5R110W.pdf

INDEX

Copyright © ATSG 2004

FORD 5R110W (Torqshift )

2

AUTOMATIC TRANSMISSION SERVICE GROUP9200 S. DADELAND BLVD. SUITE 720

MIAMI, FLORIDA 33156(305) 670-4161

IDENTIFICATION TAG LOCATION AND INFORMATION ............................................................. COMPONENT APPLICATION CHART ............................................................................................... GENERAL DESCRIPTION AND OPERATION ................................................................................... FLUID REQUIREMENTS ...................................................................................................................... ELECTRONIC COMPONENT LOCATIONS AND IDENTIFICATION ............................................ ELECTRONIC COMPONENT DESCRIPTION AND OPERATION .................................................. TRANSMISSION WIRING SCHEMATIC ............................................................................................. INTERNAL COMPONENT RESISTANCE CHART ............................................................................. LINE PRESSURE TESTS ....................................................................................................................... DIAGNOSTIC TROUBLE CODES ......................................................................................................... TRANSMISSION DISASSEMBLY ......................................................................................................... COMPONENT REBUILD TRANSMISSION CASE ...................................................................................................................... SOLENOID BODY ASSEMBLY ......................................................................................................... OIL PUMP ASSEMBLY ....................................................................................................................... COAST CLUTCH HOUSING .............................................................................................................. OVERDRIVE GEAR TRAIN SECTION ............................................................................................. CENTER SUPPORT ............................................................................................................................. INTERMEDIATE CLUTCH PLATES AND DIFFERENCES ......................................................... FORWARD CLUTCH HOUSING AND DIFFERENCES ................................................................ DIRECT CLUTCH HOUSING AND DIFFERENCES ..................................................................... FORWARD PLANETARY SYSTEM DIFFERENCES ...................................................................... SUN SHELL DIFFERENCES ............................................................................................................ DRUM AND SUN SHELL SUB ASSEMBLY ..................................................................................... REAR PLANETARY CARRIER AND DIFFERENCES ................................................................... LOW DIODE ASSEMBLY AND DIFFERENCES ............................................................................ TRANSMISSION FINAL ASSEMBLY ................................................................................................... FORWARD CLUTCH ORIFICE LOCATION ........................................................................................ TORQUE SPECIFICATIONS ................................................................................................................. SOLENOID BODY BOLT CHART AND IDENTIFICATION ............................................................. BOLT CHART AND IDENTIFICATION ............................................................................................... SPECIAL TOOLS FOR ASSEMBLY ......................................................................................................

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The new Ford 5R110W, referred to by Ford Motor Company as the "TorqShift" transmission, is a redesign of the 4R100 transmission with some previous strategy applied. This unit was introduced in model year 2003 in the F Series Trucks and the Excursion vehicles that are equipped with the new 6.0L diesel engine. The "TorqShift" (5R110W) is a 5 speed, rear wheel drive unit that actually has six forward speeds available, depending on hot or cold mode operation. The gear ratio for 1st gear was lowered from 2.71 to 3.09. For 2nd gear the overdrive clutch is applied to provide a ratio of 2.20. 3rd gear provides a ratio of 1.54, which is the same ratio as the previous second gear. All sound familiar? When in cold mode operation, below -15°C (5°F), determined by the TFT sensor, the overdrive clutch is engaged in 3rd gear to provide a ratio of 1.09 for 4th gear, and the transmission will shift directly into 6th gear (overdrive), which is a ratio of 0.71. In cold mode the transmission shifts 1st gear, 2nd gear, 3rd gear, 4th gear, 6th gear. When in hot mode the transmission will shift 1st gear, 2nd gear, 3rd gear, 5th gear (ratio 1.00), 6th gear. Either way it is still a five speed unit with six forward gear ratios available, depending on cold mode or hot mode of operation.

FORD 5R110W ("TorqShift")

INTRODUCTION

AUTOMATIC TRANSMISSION SERVICE GROUP9200 S. DADELAND BLVD. SUITE 720

MIAMI, FLORIDA 33156(305) 670-4161 1

No part of any ATSG publication may be reproduced, stored in any retrieval system or transmitted in any form or by any means, including but not limited to electronic, mechanical, photocopying, recording or otherwise, without written permission of Automatic Transmission Service Group. This includes all text illustrations, tables and charts.

The information and part numbers contained in this booklet havebeen carefully compiled from industry sources known for their

reliability, but ATSG does not guarantee its accuracy.

Copyright © ATSG 2004

PublishedMarch, 2005

DALE ENGLANDFIELD SERVICE CONSULTANT

ED KRUSETECHNICAL CONSULTANT

WAYNE COLONNATECHNICAL SUPERVISOR

PETER LUBANTECHNICAL CONSULTANT

JIM DIALTECHNICAL CONSULTANT

GREGORY LIPNICKTECHNICAL CONSULTANT

JERRY GOTTTECHNICAL CONSULTANT

JON GLATSTEINTECHNICAL CONSULTANT

DAVID CHALKERTECHNICAL CONSULTANT

ROLAND ALVAREZTECHNICAL CONSULTANT

MIKE SOUZATECHNICAL CONSULTANT

GERALD CAMPBELLTECHNICAL CONSULTANT

We wish to thank Ford Motor Companyfor the information and some illustrations

that have made this booklet possible.

3AUTOMATIC TRANSMISSION SERVICE GROUP

Technical Service Information

Figure 1

Copyright © 2003 ATSG

RF3C3P-7006-AE

FordFord

98

3C3P-7000-KB F5A4522 180302

DDMMYYPDT-25

A1F5

55FFPDT-25

303P-7000-KB

004361A4522 180302DD MM YY

1

2

3

Build Date: DD = Day, MM = Month, YY = Year

Serial Number

Transmission Model

Assembly Part Number, Prefix And Suffix1

2

3

4

4

IDENTIFICATION TAG LOCATION AND DESCRIPTION

AUTOMATIC TRANSMISSION SERVICE GROUP


4

OVERDRIVECLUTCH COAST

CLUTCH

DIRECTCLUTCH

FORWARDCLUTCH

LOW/REVERSECLUTCH

LOW OWCDIODE

O.D. OWCDIODE

INTERMEDIATECLUTCH

COMPONENT APPLICATION CHART WITH TOW/HAUL "OFF"

Range/Gear

Park/Neut

Reverse

O.D.- 1st ON (d)

ON (d)

ON (d)

ON (d)

ON (d)

ON (d)

ON (d)

ON (d)

ON (d)

HOLD

HOLD

HOLD

HOLD YES

YES

YES

O/R

O/R

O/R

O/R

O/R

O/R

O/R

O/R

O/R

HOLD

HOLD

HOLD

HOLD

HOLDON

ON

ON

ON

ON

ON

ON

ON (a) (c)

ON (a) (c)

ON (a)

ON (a)

ON (a)

ON

ON

ON

ON (d)

ON

ON

O.D.- 2nd

O.D.- 3rd

O.D.- 4th (b)

O.D.- 5th

O.D.- 6th

Man- 3rd

Man- 2nd

Man- 1st

Fwd.Clutch

Int.Clutch

DirectClutch

O.D.Clutch

CoastClutch

Lo/RevClutch

O.D.Diode

LowDiode

GearRatio

EngBrak

3.09

3.09

2.20

2.20

1.54

1.54

1.09

1.00

0.71

2.88

(a) PCM Calibration Controlled (b) Cold Strategy (See Page 6) (c) 30 psi Until 5 kmh (3 mph) (d) Clutch Applied Through Manual Valve Position

COMPONENT APPLICATION CHART

Figure 2


When the Park position is selected, there is no powerflow through the transmission. The parking pawl is engaged which locks the output shaft to the transmission case. The engine can be started and the ignition key can be removed.

When the Reverse position is selected, the vehicle can be operated in a rearward direction at a reduced gear ratio.

When the Neutral position is selected, there is no powerflow through the transmission. The output shaft is not held and is free to turn and the engine can be started. This position can also be selected while vehicle is moving, to restart the engine if that becomes necessary.

The Overdrive position is the normal position for most forward gear operations. The Overdrive position provides automatic upshifts and downshifts, apply and release of the converter clutch, and maximum fuel economy during normal operation.

The 3rd Gear position provides third gear start and hold, for improved traction on slippery roads. This position can also be selected at any vehicle speed for improved engine braking. Transmission will not downshift if it will cause an engine overspeed condition.

The 2nd Gear position provides second gear start and hold, for improved traction on slippery roads. This position can also be selected at any vehicle speed for improved engine braking. If this position is selected at higher speeds, the transmission will downshift to the next lower gear, and will downshift into second gear after the vehicle decelerates to a vehicle speed that will not create an engine overspeed condition.

The Manual Low Gear position provides 1st gear operation only. This position can also be selected at any vehicle speed to provide improved engine braking for descending steep grades. If this position is selected at higher speeds, the transmission will downshift to the next lower gear, and will downshift into first gear after the vehicle decelerates to a vehicle speed that will not create an engine overspeed condition.

GENERAL TRANSMISSIONDESCRIPTION AND OPERATION

DN 3 2 1RP

The Ford 5R110W "TorqShift" transmission has seven range positions that can be selected with the manual shift lever, P, R, N, (D), 3, 2, 1. Following is a description of each range.

P

R

N

(D)

3

2

1

TRANSTEMP

TRANSMISSIONTEMPERATURE

GAGE

There has also been added to the instrument cluster, a transmission temperature gauge that we think is long over-due, and should be on all vehicles.

Transmission Temperature Gage

Figure 3



5


Any time the battery is disconnected for any reason, a new PCM has been installed, or the calibration has been reflashed, the adaptive strategy for the "Engagement Schedule" must be updated.This procedure will prevent the customer from returning with firm or harsh engagement complaints.Procedure is as follows:Note: All of the following engagements must be performed, in order for engagement pressures to correctly adapt with the new calibration. 1. Install diagnostic equipment and monitor TFT. 2. Warm the transmission fluid to 54°C (130°F) as indicated by the TFT. 3. Perform 5 engagements from Park to Reverse. Each engagement must be five seconds apart. 4. Perform 5 engagements from Drive to Reverse. Each engagement must be five seconds apart. 5. Perform 5 engagements from Reverse to Drive. Each engagement must be five seconds apart. 6. Perform 5 engagements from Neutral to Drive. Each engagement must be five seconds apart.

TOW/HAUL ON

The Tow/Haul feature was designed to assist the driver when towing a trailer or a heavy load. All transmission gear ranges, including all five forward gears, are available when using the Tow/Haul feature. The Tow/Haul Switch is located on the end of the manual shift lever, (See Figure 4) and is a momentary contact switch. The Tow/Haul Switch provides a signal to the PCM when pressed by the operator, resulting in a change in shift and TCC scheduling. When the Tow/Haul Switch has been turned on, the indicator lamp that is located at the end of the manual shift lever will illuminate "Tow/Haul - ON". When Tow/Haul is activated, upshifts will now occur at a higher vehicle speed, and when decelerating, the downshifts will also occur at a higher vehicle speed, providing some added engine braking. When the switch is pressed again, Tow/Haul will be cancelled and the Transmission Control Indicator Lamp (TCIL) will turn off. The PCM controls the operation of the TCIL. The PCM may also flash the TCIL on and off, to alert the driver that a transmission operational error has occured, when certain faults in monitored sensors, solenoids or other transmission components are detected.

Tow/Haul Feature

Figure 4

Battery Disconnect, Dead Battery

Cold Mode Operation

The "TorqShift" (5R110W) is a 5 speed, rear wheel drive unit that actually has six forward speeds available, depending on hot or cold mode operation. The gear ratio for 1st gear was lowered from 2.71 to 3.09. For 2nd gear the overdrive clutch is applied to provide a ratio of 2.20. 3rd gear provides a ratio of 1.54, which is the same ratio as the previous second gear. All sound familiar? When in cold mode operation, below -15°C (5°F), determined by the TFT sensor, the overdrive clutch is engaged in 3rd gear to provide a ratio of 1.09 for 4th gear, and the transmission will shift directly into 6th gear (overdrive), which is a ratio of 0.71. In cold mode the transmission shifts 1st gear, 2nd gear, 3rd gear, 4th gear, 6th gear. When in hot mode the transmission will shift 1st gear, 2nd gear, 3rd gear, 5th gear (ratio 1.00), 6th gear. Either way it is still a five speed unit with six forward gear ratios available, depending on cold mode or hot mode of operation.



6




7

The new Ford 5R110W "TorqShift" transmission also uses a new transmission fluid called Mercon®SP, and is not interchangeable with Mercon® or Mercon®V. The use of any other transmission fluid than Mercon®SP, can result in the transmission failing to operate in a normal manner and/or transmission failure. Ford recommends the transmission fluid and bottom pan filter be changed every 48,000 km (30,000 miles) regardless of normal or special operating conditions.

Fluid Requirements Mercon®SP

REMOTE TRANSMISSION FILTER IN COOLER LINES

Remote Transmission Filter

This transmission is equipped with a remote fluid filter, as shown in Figure 5. This filter passes ten percent of the transmission fluid from the transmission through a small orifice into a servicable screw-on filter element. The filtered fluid is then directed back into the rear lube circuit through the large opening in the remote filter manifold.

1 OIL TO AIR TRANSMISSION FLUID AUXILIARY COOLER 2 REAR "FROM COOLER" LINE CASE FITTING 3 FRONT "TO COOLER" LINE CASE FITTING 4 REMOTE FILTER "IN" LINE 5 COOLER LINE BRACKET 6 NUT 7 STUD 8 RADIATOR COOLER "IN" LINE 9 COOLER LINE "C" CLIP10 COOLER LINE CLIP11 REMOTE FILTER MANIFOLD BRACKET12 REMOTE TRANSMISSION FLUID FILTER13 HOSE ASSEMBLY

Oil To Air AuxiliaryTrans Cooler

Radiator In-TankTrans Cooler

Remote FilterManifold

5R110WTrans

Cooler FlowSchematic

Figure 5

CAUTION: The transmission cooler lines must be disconnected prior to flushing out the cooler lines. Do Not attempt to flush the remote filter housing because of the internal orifice.

Turbine Shaft Speed Sensor andIntermediate Shaft Speed Sensor

Output Shaft Speed Sensor

TransmissionRange Sensor

PC-A

PC-A = Line Pressure SolenoidTCC = Torque Converter Clutch SolenoidSSPC-A = Shift Solenoid A (Coast Clutch)SSPC-B = Shift Solenoid B (Overdrive Clutch)SSPC-C = Shift Solenoid C (Intermediate Clutch)SSPC-D = Shift Solenoid D (Direct Clutch)SSPC-E = Shift Solenoid E (Low/Reverse Clutch)

TCC

SSPC-B

SSPC-C

SSPC-E

SSPC-D

SSPC-A

PS-A

SOLENOIDBODY

PS-A = Pressure Switch A (Coast Clutch)PS-B = Pressure Switch B (Overdrive Clutch)PS-C = Pressure Switch C (Intermediate Clutch)PS-D = Pressure Switch D (Direct Clutch)PS-E = Pressure Switch E (Low/Reverse Clutch)TFT = Transmission Fluid Temperature Sensor

PS-B

TFTSensor

PS-E

PS-D

PS-C

Figure 6

ELECTRONIC COMPONENT LOCATIONS AND IDENTIFICATION



8


ELECTRICAL COMPONENTDESCRIPTION AND OPERATION

The following provides a brief description of each of the sensors and actuators used by the PCM for proper transmission operation

Powertrain Control Module (PCM)

Brake Pedal Position (BPP) Switch

Tow/Haul Switch

Transmission Control Indicator Lamp (TCIL)

Engine Coolant Temperature (ECT) Sensor

Intake Air Temperature (IAT) Sensor

4 X 4 Low Switch

Accelerator Pedal Position (APP) Sensor

The operation of the transmission is controlled by the Powertrain Control Module (PCM). Many input sensors provide information to the PCM. The PCM then uses this information to control actuators which determine transmission operation. Refer to Figure 14 for PCM location and connector terminal information and identification.

The brake pedal position (BPP) switch supplies battery voltage to the PCM, that the brake pedal is applied. The PCM uses this information to release the torque converter clutch, speed control, and auxiliary idle (if equipped).

The Tow/Haul Switch is located on the end of the manual shift lever and is a momentary contact switch. The Tow/Haul Switch provides a signal to the PCM when pressed by the operator, resulting in a change in shift and TCC scheduling. When the Tow/Haul Switch has been pressed, the indicator lamp that is located at the end of the manual shift lever will illuminate "Tow/Haul - ON". When the switch is pressed again, Tow/Haul will be cancelled and the TCIL will turn off (See Figure 4).

The TCIL is used along with the Tow/Haul Switch. The TCIL is located near the end of the manual shift lever and will illuminate "Tow/Haul - ON" when the Tow/Haul switch has been pressed. The PCM controls the operation of the TCIL. The PCM may also flash the TCIL on and off, to alert the driver that a transmission operational error has occured, when certain faults in monitored sensors, solenoids or other transmission components are detected (See Figure 4).

The engine coolant temperature (ECT) sensor is a thermistor in which resistance changes when the temperature changes. The resistance of the sensor increases as engine temperature decreases and the voltage sent to the PCM increases. The PCM uses this information to help determine TCC operation.

The intake air temparature (IAT) sensor is a thermistor in which the resistance changes with temperature. The resistance decreases as the intake air temperature increases. The IAT provides air temperature information to the PCM, which is used to help determine transmission line pressure and shift scheduling.

The 4X4 Low Switch, located on the dash on the right hand side of the driver, sends a ground signal to the instrument cluster when the vehicle is in 4X4 Low. The PCM then receives 4X4 Low status from the instrument cluster and adjusts the transmission shift schedule accordingly. Four wheel "High" can be selected while moving at any speed up to 55 MPH.

The accelerator pedal position (APP) sensor is mounted on the accelerator pedal on 6.0L diesel applications. The APP sensor detects the position of the accelerator pedal and inputs this information, as a voltage to the PCM. The PCM uses APP sensor information to help in determining line pressure, shift scheduling and TCC operation. Failure of the APP sensor will cause transmission to operate at a higher than normal line pressure to help avoid damage to the transmission. This will result in harsh upshifts and harsh engagements.



9


The coast (SSPC-A), and direct (SSPC-D) clutch packs are each controlled by an inversely proportional three port solenoid. The pressure output is inversely proportional to the applied DC current supplied through an electronically controlled driver. The current is varied between 0 amp and 1 amp from the PCM, and 0 amp equals maximum pressure in the particular clutch oil circuit. The Shift Solenoid controls the apply and release rates of the particular clutch pack. Refer to Figure 8.

The Solenoid Body Assembly is bolted to the transmission case inside the bottom pan and looks similar to what we have previously referred to as a valve body. The Solenoid Body Assembly contains the following: Seven Variable Force Solenoids Five Normally Closed Pressure Switches Transmission Fluid Temperature Sensor Manual Shift Valve Over-Pressurization Relief BallThere is a solenoid and a pressure switch dedicated to the function of each clutch pack, except the forward clutch, as it is controlled by the manual valve. There are no other valves in the solenoid body except for the pressure relief ball and spring. All shifts are controlled by five solenoids. Line pressure and the torque converter clutch each have their own solenoid. Four of the solenoids, TCC, OD Clutch, Intermediate Clutch and the Low/Reverse Clutch, are directly proportional which means the pressure output is directly proportional to the applied DC amps. The current is varied between 0 and 1 amp from the PCM, and 1 amp equals maximum pressure in the oil circuit. Three of the solenoids, Line Pressure, Coast Clutch and Direct Clutch, are inversely proportional which means the pressure output is inversely proportional to the applied DC amps. The current is varied between 0 and 1 amp from the PCM, and 0 amp equals maximum pressure in the oil circuit.The different design solenoids are keyed differently to prevent mis-assembly in the solenoid body and all are retained with a large "E" clip. The "Natural" colored wire connectors connect to the solenoids. The "Black" colored connectors connect to the pressure switches. There are separate connectors for the TFT sensor and for the TR-P sensor. All of the solenoids except the line pressure solenoid can be serviced without removing the solenoid body from the case. Refer to Figure 6 for location and identification of the solenoids and switches on the solenoid body. Refer to Figure 8 for the differences and how to identify between the direct and inversely proportional solenoids.

ELECTRICAL COMPONENTDESCRIPTION AND OPERATION (Cont'd)

Transmission Solenoid Body Assembly

Line Pressure Control Solenoid (PC-A)

Torque Converter Clutch (TCC) Solenoid

Shift Solenoid Pressure Control Solenoids(SSPC-B, SSPC-C, SSPC-E)

Shift Solenoid Pressure Control Solenoids(SSPC-A, SSPC-D)

The Line Pressure Control Solenoid (PC-A) is an inversley proportional three port solenoid. The pressure output is inversely proportional to the applied DC current supplied through an electronically controlled driver. The current is varied between 0 amp and 1 amp from the PCM, and 0 amp equals maximum pressure in the oil circuit. The PC-A Solenoid controls the line pressure oil circuits (See Figure 8)

The Torque Converter Clutch (TCC) Solenoid is a directly proportional three port solenoid. The pressure output is directly proportional to the applied DC current supplied through an electronically controlled driver. The current is varied between 0 amp and 1 amp from the PCM, and 1 amp equals maximum pressure in the oil circuit. The TCC Solenoid controls the apply and release rates of the converter clutch (See Figure 8).

The overdrive (SSPC-B), intermediate (SSPC-C), and low/reverse (SSPC-E) clutches are each controlled by a directly proportional three port solenoid. The pressure output is directly proportional to the applied DC current supplied through an electronically controlled driver. The current is varied between 0 amp and 1 amp from the PCM, and 1 amp equals maximum pressure in the particular clutch oil circuit. The Shift Solenoid controls the apply and release rates of the particular clutch pack (See Figure 8).



10


3C 383 3P7GCA


Pressure Switches(PS-A, PS-B, PS-C, PS-D, PS-E)


Each of the five shift pressure control solenoids has a corresponding pressure switch, which is normally closed. The pressure switch is designed to open when shift solenoid control pressure exceeds 40 psi. All five of the pressure switches are identical and will interchange in the solenoid body, as shown in Figure 7. Their particular functions are as follows:PS-A = Coast ClutchPS-B = Overdrive ClutchPS-C = Intermediate ClutchPS-D = Direct ClutchPS-E = Low/Reverse ClutchRefer to Figure 6 for their particular locations in the solenoid body.

3C 383 3P7GBA

TCC, SSPC-B, SSPC-C, SSPC-E"Directly" Proportional Solenoids

(1 Amp = Maximum Pressure)

PC-A, SSPC-A, SSPC-D"Inversely" Proportional Solenoids


Retaining"E" Clip

Retaining Clip

PressureSwitch

Boot/Seal

Retaining"E" Clip

LocatingTabs "High" Locating

Tabs "Low"

AdjustingScrew

Rear View Rear ViewFront View Front View

Figure 8

Figure 7



11



Special Note: Use of the pressure switch input was dropped from the vehicle calibration before the 2003 model year went into production.

(1)

(2)

(3)

(4)

Turbine Shaft AndIntermediate Shaft

Speed Sensor

Gray/Orange

Green/White

Pink/White

Black/White

View Looking IntoTurbine Shaft And

Intermediate Shaft SpeedSensor Connector

TSS Sig

Grnd

Ref Volt

ISS Sig

Output ShaftSpeed Sensor

(TSS) Terminals 1 and 3 = 325-485 Ohms @ 70°F

(OSS) Terminals 1 and 2 = 325-485 Ohms @ 70°F

(ISS) Terminals 1 and 4 = 325-485 Ohms @ 70°F

Pink/White(1)

(2)

(3)Black/White

Blue/Yellow

View Looking IntoOutput Shaft SpeedSensor Connector

Grnd

Ref Volt

OSS Sig

Turbine Shaft Speed (TSS) Sensor andIntermediate Shaft Speed (ISS) Sensor

Output Shaft Speed (OSS) Sensor

Cold Mode/Hot Mode Operation



The turbine shaft speed (TSS) and intermediate shaft speed (ISS) sensors are hall effect sensors requiring a 12-volt power supply and a ground. In this unit both sensors are incorporated into one housing. The other two terminals at the sensor are for TSS and ISS signals to the PCM. The sensor detects teeth on the coast clutch input hub for TSS signal, and the adjacent overdrive ring gear teeth for the ISS signal. Both sensors read 30 teeth per revolution. The TSS/ISS sensors are mounted externally on the transmission case (See Figure 6). The TSS/ISS sensors input to the PCM is digital and used to determine line pressure, shift timing and TCC operation. Refer to Figure 9 for TSS/ISS sensor illustrations and connector information.

The transmission output shaft speed (OSS) sensor is located on the extension housing (See Figure 6). The OSS is a hall effect type sensor. The OSS reads a set of gear teeth on the park gear, that are different than the teeth used for the park function. The OSS signal to the PCM is used for vehicle speed signal, shift scheduling and TCC operation. The OSS has bi-directional capability and uses a digital output. The OSS tone wheel has 3 different width spaces between its teeth. The PCM uses the difference in pulse width to identify shaft direction rotation. Refer to Figure 10 for OSS sensor illustrations and connector information.

When the transmission is in cold mode operation, below -15°C (5°F), determined by the TFT sensor, the transmission shifts 1st gear, 2nd gear, 3rd gear, 4th gear (ratio 1.09), 6th gear. When in hot mode the transmission will shift 1st gear, 2nd gear, 3rd gear, 5th gear (ratio 1.00), 6th gear. Either way it is still a five speed unit with six forward gear ratios available, depending on cold mode or hot mode of operation.


Figure 10

Figure 9



12


(1)

(2)

(3)

View Looking IntoTransmission Range

Sensor Connector

Grnd

Ref Volt

TR-P SigPurple

Pink

Orange

View Looking IntoTransmission Range

Sensor Assembly

Transmission Range Sensor Assembly

Transmission Range (TR-P) Sensor Assembly

Transmission Fluid Temperature (TFT) Sensor

The transmission range (TR-P) sensor assembly, shown in Figure 11, is an internally mounted sensor that includes the detent spring, rooster comb lever and bracket, located next to the solenoid body and bolted to the transmission case. The transmission range sensor is non-adjustable and is not serviced independently. The TR-P sensor contains electronic circuitry that provides the PCM a fixed frequency, at a duty cycle, for each of the seven positions of the manual shift lever. Refer to Figure 11 for the duty cycle specifications for the various positions. The PCM uses the TR-P sensor signal for starting in Park and Neutral only, reverse lamp operation, and for line pressure control, shift scheduling and TCC operation.

DN 3 2 1RP

TR-P Duty Cycle Chart

Position Min % Duty Cycle

7.13

22.94

36.65

48.56

58.83

68.09

77.97

Max % Duty Cycle

22.93

36.64

48.55

58.82

68.08

77.96

90.34

P

R

N

D

3

2

1

Resistance(Ohms)Degrees F

Transmission Fluid Temperature (TOT)

Degrees C

-40 to -20 -40 to -4

-3 to 31

32 to 68

967k to 284k

284k to 100k

100k to 37k

37k to 16k

16k to 5k

5k to 2.7k

2.7k to 1.5k

1.5k to 0.8k

0.8k to 0.54k

69 to 104

105 to 158

159 to 194

195 to 230

231 to 266

267 to 302

-19 to -2

0 to 20

21 to 40

41 to 70

71 to 90

91 to110

111 to130

131 to150

The transmission fluid temperature (TFT) sensor twist-locks into the solenoid body and is a temperature sensitive device called a thermistor. As the fluid temperature increases, the TFT resistance decreases, as shown in the chart in Figure 12. The PCM uses the TFT signal as an input to determine cold and hot temperature shift scheduling and for TCC apply and release scheduling.


Figure 11 Figure 12



13


5R110W TRANSMISSION CASE CONNECTOR PIN FUNCTIONS

PinNumber

1

3

4

5

7

8

9

10

11

12

13

14

15

16

17

18

20

21

22

24

Special Note: Pin Numbers 2, 6, 19, and 23 are not used.

Description

Ground signal to Shift Solenoid Pressure Control "E" (SSPC-E)

Ground signal to Shift Solenoid Pressure Control "B" (SSPC-B)

Ground signal to Shift Solenoid Pressure Control "C" (SSPC-C)

Ground signal to Shift Solenoid Pressure Control "D" (SSPC-D)

Ground signal to Shift Solenoid Pressure Control "A" (SSPC-A)

Ground signal to Torque Converter Clutch (TCC) Solenoid

VPWR to Pressure Control (PC-A) Solenoid and TCC Solenoid

Ground signal to Pressure Control (PC-A) Solenoid (Line Pressure)

Pressure Switch "C" (PS-C), Intermediate Clutch Signal to PCM

Pressure Switch "D" (PS-D), Direct Clutch Signal to PCM

Pressure Switch "A" (PS-A), Coast Clutch Signal to PCM

Pressure Switch "E" (PS-E), Low/Reverse Clutch Signal to PCM

Pressure Switch "B" (PS-B), Overdrive Clutch Signal to PCM

Transmission Range - Park (TR-P) Sensor, Signal to PCM

Transmission Range - Park (TR-P) Sensor, Ground

VPWR to Transmission Range - Park (TR-P) Sensor Only

Pressure Switches and TFT Sensor ground

VPWR to SSPC-A and SSPC-B Solenoids

Transmission Fluid Temperature (TFT) Sensor signal to PCM

VPWR to SSPC-C, SSPC-D and SSPC-E Solenoids

24 22

13 57

4

910

8

1112

1314

1516

1721

1820

View Looking IntoFace Side Of VehicleHarness Connector

View Looking IntoWire Side Of VehicleHarness Connector

2422

1 35 7

4

9 10

8

11 12

13 14

15 16

17 21

18 20

2

6

19

23

Figure 13



14


Powertrain ControlModule (PCM)

Behind the LeftHand Battery

PCM Connector A

MAFConnector

ConnectorC1010

ConnectorC1282

ConnectorC1298

AuxiliaryRelay Box 5

AuxiliaryRelay Box 3

PCM Connector C

PCM Connector B

7

15 8

1

22 16

30 23

View Looking IntoFace Side Of VehiclePCM Connector "B"

Pin Pin

1 16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Wire Color Wire Color

Pink/White

White/Yellow

Dk Blue/Pink

Pink/Lt Blue

Lt Blue/Yellow

Dk Blue/Yellow

Orange/Black

Orange/White

Gray/Orange

Lt Blue/Red

White/Red

Black/White

Green/White

Red/White

Violet/Yellow

Violet/Orange

Brown/Orange

Pink/Black

Black/Lt Green

Dk Blue/White

Orange/Yellow

Yellow/Lt Green

Yellow/White

White/Lt Green

Circuit Function Circuit Function

12V Reference Voltage, Speed Sensors and TRP

Both Speed Sensors and TR-P Ground

TR-P Transmission Range Sensor Signal

TFT Transmission Fluid Temp Sensor Signal

ISS Intermediate Shaft Speed Sensor Signal

OSS Output Shaft Speed Sensor Signal

TSS Turbine Shaft Speed Sensor Signal

Pressure Switch And TFT Sensor Ground

PC-A Pressure Control Solenoid Ground

SSPC-A Shift Solenoid Pressure Control A Ground

SSPC-B Shift Solenoid Pressure Control B Ground

SSPC-C Shift Solenoid Pressure Control C Ground

SSPC-D Shift Solenoid Pressure Control D Ground

SSPC-E Shift Solenoid Pressure Control E Ground

TCC Torque Converter Clutch Solenoid Ground

Transfer Case Neutral Signal

Reverse Lamp Relay, Control

TCIL, Control (Tow/Haul)

"Not Used"

"Not Used"

"Not Used"

"Not Used"

"Not Used"

"Not Used"

PS-A Pressure Switch "A" Signal

PS-B Pressure Switch "B" Signal

PS-C Pressure Switch "C" Signal

PS-D Pressure Switch "D" Signal

PS-E Pressure Switch "E" Signal

12V Power to Solenoids

5R110W PCM CONNECTOR "B" PIN IDENTIFICATION AND FUNCTIONSAND PCM LOCATION

Figure 14



15


PS-ACoastClutch

PS-BO.D.

ClutchInt.

Clutch

PS-DDirectClutch

PS-ELo/RevClutch

SSPC-A

CoastClutch

SSPC-B

OverdriveClutch

SSPC-C

IntermediateClutch

SSPC-D

DirectClutch

SSPC-E

Low/ReverseClutch

PC-A

LinePressure

TCC

ConverterClutch

PS-C

7

10

8

20

12

3

24

5

4

1

18

17

15

21

14

16

9

11

13

22

7

2

14

7

9

10

7

11

12

13

26

22

25

1

17

18

19

20

21

30

22

29

27

28

22

1

1

TR-PConnector

2 31

TFTSensor

Gra

y

Pu

rple

Pu

rple

Pu

rple

Pu

rple

Pu

rple

Pin

k

Pin

kPin

k

Pin

k

Pin

k

Pin

k

Bla

ck

Bla

ck

Gra

y

Gra

y

Red

Ta

n

Pu

rple

Ora

nge

Yellow/White

(Inverse) (Inverse) (Inverse)(Direct) (Direct) (Direct) (Direct)

Dk. Blue/White

Dk. Blue/Pink

Lt. Blue/Yellow

Lt. Blue/Red

Pink/Lt. Blue

Yellow/White

Yellow/White

Pink/Black

Orange/Black

Orange/White

Black/Lt. Green

Black/White

Pink/White

Pink/White

Pink/White

Black/White

Black/White

Gray/Orange

Green/WhiteTSS Sig

Grnd

Grnd

Ref Volt

Ref Volt

ISS Sig

OSS SigDk. Blue/Yellow

White/Red

White/Yellow

Violet/Yellow

Violet/Orange

Orange/Yellow

Brown/Orange

Ora

nge

Ora

nge

Ora

ngeO

ran

ge

Ora

nge

Ta

n

Ta

n

Ta

n

Red

5R110W INTERNAL WIRE SCHEMATIC

5R110W Tranmission

2

3

4

1Turbine Shaft AndIntermediate Shaft

Speed SensorAssembly

2

3

1


Assembly

PO

WE

RT

RA

IN C

ON

TR

OL

MO

DU

LE

(P

CM

)

PCMCONNECTOR "B"(See Connector I.D.)

(Figure 14)

TRANS CASECONNECTOR

(See Connector I.D.)(Figure 16)

Figure 15



16


INTERNAL COMPONENT RESISTANCE CHART

INTERNALCOMPONENT

CASE CONNECTORPIN NUMBERS

OHMSRESISTANCE

SSPC-E Soleniod

SSPC-D Soleniod

SSPC-C Soleniod

SSPC-B Soleniod

SSPC-A Soleniod 12 and 20 4.1 to 4.7 @ 72° F

4.1 to 4.7 @ 72° F

4.1 to 4.7 @ 72° F

4.1 to 4.7 @ 72° F

4.1 to 4.7 @ 72° F

4.1 to 4.7 @ 72° F

4.1 to 4.7 @ 72° F

5.1 to 5.8 @ 72° F

0.5 Ohms @ 72° F

0.5 Ohms @ 72° F

0.5 Ohms @ 72° F

0.5 Ohms @ 72° F

0.5 Ohms @ 72° F

See Chart Below

3 and 20

5 and 24

4 and 24

1 and 24

7 and 10

7 and 10

7 and 8

14 and 22

16 and 22

9 and 22

11 and 22

13 and 22

18 and 22

See Figure 11

See Figure 9

See Figure 10

PC-A Solenoid (Early)

PC-A Solenoid (Late)

TCC Solenoid

PS-A

PS-B

PS-C

PS-D

PS-E

TFT

TR-P Sensor

TSS/ISS Sensor

OSS Sensor

** Internal WireColors At Component

Connector

Purple and Orange

Purple and Orange

Black and Pink

Tan and Pink

Pink and Black

Red and Gray

Gray and Orange

Orange and Pink

** Wire colors may vary.

Red and Tan

Orange and Purple

Tan and Pink

Tan and Purple

Gray and Purple

Gray and Purple

View Looking IntoTransmission Case

Connector

2422

1 35 7

4

9 10

8

11 12

13 14

15 16

17 21

18 20

Resistance(Ohms)Degrees F

Transmission Fluid Temperature (TOT)

Degrees C

-40 to -20 -40 to -4

-3 to 31

32 to 68

967k to 284k

284k to 100k

100k to 37k

37k to 16k

16k to 5k

5k to 2.7k

2.7k to 1.5k

1.5k to 0.8k

0.8k to 0.54k

69 to 104

105 to 158

159 to 194

195 to 230

231 to 266

267 to 302

-19 to -2

0 to 20

21 to 40

41 to 70

71 to 90

91 to110

111 to130

131 to150

Figure 16



17


LINE PRESURE TESTS

RF3C3P-7006-AE

FordFord

98

3C3P-7000-KB F5A4522 180302

DDMMYYPDT-25

A1F5

lllll ll ll ll ll ll ll ll ll ll ll ll ll ll ll ll ll ll llll llll ll

Range

P/N

R

(D)

3

2

1

Idle Speed

LINE PRESSURE CHART

50 psi

100 psi 320 psi

320 psi

260 psi

270 psi

215 psi

70 psi

80 psi

80 psi

80 psi

Stall Speed

PRECAUTIONS:

(1) Certain sensor failures may cause high line pressure and Failure Mode Effect Management (FMEM) actions. Ensure that on-board diagnostic and electrical repairs have been carried out first, or test results may be incorrect.

(2) Perform the line pressure test in all ranges prior to performing the Stall Speed Test. If line pressure is low at idle, "Do Not" carry out the Stall Speed Test or additional transmission damage will occur. Do not maintain wide open throttle (WOT) in any range for more than 5 seconds or transmission damage may occur.

(3) Apply the parking brake and block wheels during the line pressure test. Vehicle movement during the test may cause personal injury or damage to the vehicle and equipment.

Figure 17

All Pressures Listed Are Approximate



18


FORD 5R110WAbbreviation Description

Abbreviation AbbreviationDescription Description

4X4L

ACCS

A/C

ABS

APP

APGND

BARO

BPP

BUS -

BUS +

CASE GND

CMP

CID

DLC

DTC CNT

DTC

ECT

EOT

FUEL PW

FEPS

GPC

GP

GPL

IAT

ISS

ICP

IPR

IVS

KAM

KAPWR

KOEO

KOER

MAF

OSS

PCM

PC-A

PS-A

PS-B

PS-C

PS-D

PS-E

RPM

ROM

SCCS

SSPC-A

SSPC-B

SSPC-C

SSPC-D

SSPC-E

TCC

TAC

TCIL

TCS

TFT

TP

TR-P

TSS

VPWR

VREF

VSS

WOT

OWC

4X4 Low Switch

Antilock Brake System

Air Conditioning Clutch Status

Air Conditioning

Accelerator Pedal Position Sensor

Accelerator Pedal Sensor Ground

Barometric Pressure Sensor

Brake Pedal Position

Data Link Connector

Data Link Connector

Case Ground

Camshaft Position Sensor

Cylinder Identification

Data Link Connector

Diagnostic Trouble Code Count

Diagnostic Trouble Code

Engine Coolant Temperature

Fuel Pulse Width

Flash EPROM Power Supply

Glow Plug Control Duty Cycle

Glow Plug

Intake Air Temperature

Glow Plug Lamp

Injector Control Pressure Sensor

Injector Pressure Regulator

Interm. Shaft Speed Sensor

Idle Validation Switch

Keep Alive Memory

Keep Alive Power

Key On Engine Off

Key On Engine Running

Mass Air Flow Sensor

Output Shaft Speed Sensor

Powertrain Control Module

Pressure Control Solenoid "A"

Pressure Switch "A"

Pressure Switch "B"

Pressure Switch "C"

Pressure Switch "D"

Pressure Switch "E"

Engine Speed

Read Only Memory

Speed Control Command Switch

Shift Solenoid Pressure Control A

Shift Solenoid Pressure Control B

Shift Solenoid Pressure Control C

Shift Solenoid Pressure Control D

Shift Solenoid Pressure Control E

Torque Converter Clutch

Tachometer Signal

Trans Control Indicator Lamp

Transmission Control Switch

Transmission Fluid Temperature

Transmission Range Sensor

Throttle Position Sensor

Turbine Shaft Speed Sensor

Vehicle Power Supply

Vehicle Reference Voltage

Vehicle Speed Sensor

Wide Open Throttle

One Way Clutch

Engine Oil Temperature

Figure 18



19


5R110W Diagnostic Trouble Code Chart

Diagnostic Code DescriptionSymptomMass Air Flow (MAF)sensor

Intake Air Temperature(IAT) sensor



Engine Coolant Temp(ECT) sensor



Throttle Position (TP) or(APP) sensor

(EI) Systems

Antilock Brake Systems(ABS)

Antilock Brake Systems(ABS)

Transmission Range(TR-P) Sensor

P0102P0103P1100P1101

P0112

P0113

P0114

P0116

P0117

P0118

P0500

P0503

P0706

MAF sensor system fails to operate in a normal manner, which may cause a transmission concern.

IAT sensor exceeds the scale set for temperature of 254°F.

ECT sensor exceeds the scale set for temperature of 254°F.

IAT sensor exceeds the scale set for temperature of minus 40°F.

ECT sensor exceeds the scale set for temperature of minus 40°F.

IAT sensor higher or lower than expected during KOEO and KOER test.

ECT sensor temperature higher or lower than expected during KOEO or KOER

P0121P0122P0123P1120P1121P1124P1125

(TP) Throttle Position sensor or (APP) Accelerator Pedal Position sensor above or below normal specifications during normal operation.

P0300P0308P0320P0340

P1351-1364

(DI) Distributor Ignition circuit concern or (CKP) Crankshaft Position sensor failure.

PCM detected a loss of VSS signal through SCP link from ABS.

PCM detected an intermittent loss of VSS signal through SCP link from ABS.

Transmission Range sensor signal frequency is out of normal range

Figure 19



20



Diagnostic Code

Figure 20

P0707

P0708

P0711

P0712

P0713

P0715

P0717

P0718

P0720

P0721

P0722

P0730

P0740

P0741

P1711

P1783

P1705

Transmission Range sensor signal duty cycle is below threshold, sensor/circuit elect. malfunction.

Transmission Range sensor signal duty cycle is above threshold, sensor/circuit elect. malfunction.

Transmission Range sensor circuit failure, or KOEO or KOER not run in P or N positions.

PCM has detected no TFT change during operation. Stuck at some normal reading.

Voltage drop across TFT sensor exceeds scale set for temperature of 315°F.

Voltage drop across TFT sensor exceeds scale set for temperature of minus 40°F.

Transmission not operating at normal temperature during On-Board diagnostics.

Transmission over temp condition indicated.

PCM detected a loss of TSS signal during normal operation.

PCM detected a loss of OSS signal during normal operation.

PCM has detected a noisy TSS signal.

PCM has detected a noisy OSS signal.

PCM has not detected a TSS signal.

PCM has detected no OSS signal.

PCM has detected a gear ratio error.

TCC Solenoid, Electrical, Open Circuit.

TCC slippage detected during engagement.Mechanical or Hydraulic concern.

DescriptionSymptom




Trans Fluid Temp(TFT) Sensor





Turbine Shaft Speed(TSS) Sensor



Output Shaft Speed(OSS) Sensor



Clutch Control Solenoidor Internal Problem

TCC Solenoid

TCC Solenoid



21



Diagnostic Code

Figure 21

P0742

P0743

P0744

P0748

P0960

P0962

P0963

P0750

P0751

P0752

P0753

P0972

P0973

P0974

P0755

P0756

P0757

P1744

TCC Solenoid circuit, shorted to ground.

PC-A Solenoid circuit, shorted to ground.

SSPC-A Solenoid circuit, shorted to ground.

PC-A Solenoid circuit, shorted to power.

SSPC-A Solenoid circuit, shorted to power.

TCC Solenoid circuit, shorted to power.

TCC Solenoid circuit failure.

TCC slippage detected during engagement.Mechanical or Hydraulic concern.

PC-A Solenoid circuit failure.

SSPC-A Solenoid circuit open failure.

SSPC-B Solenoid circuit open failure.

SSPC-A Solenoid circuit, or solenoid failure OFF.

SSPC-B Solenoid circuit, or solenoid failure OFF.

SSPC-A Solenoid circuit, or solenoid failure OFF.

SSPC-A Solenoid circuit, or solenoid failure ON.

SSPC-B Solenoid circuit, or solenoid failure ON.

SSPC-A Solenoid circuit failure.

PC-A Solenoid circuit open failure.

DescriptionSymptom

TCC Solenoid

TCC Solenoid

TCC Solenoid

TCC Solenoid

Line Pressure Control(PC-A) Solenoid




SSPC-A Solenoid(Coast Clutch)







SSPC-B Solenoid(Overdrive Clutch)





22



Diagnostic Code

Figure 22

P0758

P0975

P0976

P0977

P0760

P0761

P0762

P0978

P0979

P0980

P0981

P0982

P0983

P0765

P0766

P0767

P0768

SSPC-B Solenoid, or shorted to ground.

SSPC-B Solenoid, or shorted to power.

SSPC-D Solenoid circuit failure.

SSPC-C Solenoid, or circuit shorted to ground.

SSPC-D Solenoid, or circuit shorted to ground.

SSPC-D Solenoid, or circuit shorted to power.

SSPC-C Solenoid, or circuit shorted to power.

SSPC-B Solenoid circuit failure.

SSPC-D Solenoid circuit open failure.

SSPC-B Solenoid circuit, or solenoid failure OFF.

SSPC-C Solenoid circuit, or solenoid failure OFF.

SSPC-C Solenoid circuit, or solenoid failure OFF.

SSPC-D Solenoid circuit, or solenoid failure OFF.

SSPC-D Solenoid circuit, or solenoid failure OFF.

SSPC-C Solenoid circuit, or solenoid failure ON.

SSPC-D Solenoid circuit, or solenoid failure ON.

SSPC-C Solenoid circuit open failure.

DescriptionSymptom





SSPC-C Solenoid(Intermediate Clutch)






SSPC-D Solenoid(Direct Clutch)









23



Diagnostic Code

Figure 23

P0770

P0771

P0772

P0773

P0984

P0985

P0986

P0791

P0793

P0794

P0840

P0841

P0845

P0846

P0870

P0871

SSPC-E Solenoid, or circuit shorted to ground.

SSPC-E Solenoid, or circuit shorted to power.

Insuffecient input from ISS.

No input from ISS.

ISS signal intermittent.

Pressure Switch C circuit error, stuck open or closed, shorted to power or ground.

Pressure Switch C circuit error, stuck open or closed, shorted to power or ground.

Pressure Switch B circuit error, stuck open or closed, shorted to power or ground.

Pressure Switch B circuit error, stuck open or closed, shorted to power or ground.

Pressure Switch A circuit error, stuck open or closed, shorted to power or ground.

Pressure Switch A circuit error, stuck open or closed, shorted to power or ground.

SSPC-E Solenoid circuit, or solenoid failure OFF.

SSPC-E Solenoid circuit, or solenoid failure OFF.

SSPC-E Solenoid circuit, or solenoid failure ON.

SSPC-E Solenoid circuit open failure.

SSPC-E Solenoid circuit failure.

DescriptionSymptom

SSPC-E Solenoid(Low/Reverse Clutch)







Intermediate ShaftSpeed Sensor (ISS)



Pressure Switch A(PS-A)

Pressure Switch A(PS-A)

Pressure Switch B(PS-B)

Pressure Switch B(PS-B)

Pressure Switch C(PS-C)

Pressure Switch C(PS-C)



24



Diagnostic Code

Figure 24

P0875

P0876

P0987

P0988

P1124

P1460

P1572

P1636

P1703

P1780

P1729

P1781

P2700

P2701

P2702

P2703

P2704

Pressure Switch D circuit error, stuck open or closed, shorted to power or ground.

Pressure Switch D circuit error, stuck open or closed, shorted to power or ground.

Pressure Switch E circuit error, stuck open or closed, shorted to power or ground.

Pressure Switch E circuit error, stuck open or closed, shorted to power or ground.

Throttle position was not in proper correct position for the On-Board diagnostics.

A/C pressure cycling switch error.

Brake Pedal Position Switch, circuit failure.

Transmission Control Switch voltage incorrect.

4X4 Low Switch circuit or switch failure.

4X4 Low Switch or circuit, out of self test range.

Friction element apply time, range, or functional error detected.





Brake Pedal not cycled during KOER test, or brake ON circuit failure during KOEO.

PCM detected an error with the ISIG chip.Replace the PCM

DescriptionSymptom

Pressure Switch D(PS-D)

Pressure Switch D(PS-D)

Pressure Switch E(PS-E)

Pressure Switch E(PS-E)

Throttle Position (TP) or(APP) sensor

A/C Switch

Brake Pedal Position(BPP) Switch

Brake Pedal Position(BPP) Switch

Transmission ControlSwitch (TCS)

4X4 Low Switch

4X4 Low Switch

Coast ClutchSystem Error

Overdrive ClutchSystem Error

Intermediate ClutchSystem Error

Direct ClutchSystem Error

Low/Reverse ClutchSystem Error

SSx ISIG



25




26


RF3C3P-7006-AE

FordFord

98

3C3P-7000-KB F5A4522 180302

DDMMYYPDT-25

A1F5

TRANSMISSION DISASSEMBLYEXTERNAL COMPONENTS

Figure 25

Figure 27Figure 26


RETAININGBOLTOUTPUT SHAFT

SPEED SENSOR

OUTPUT SHAFTSPEED SENSOR

"O" RINGEXTENSIONHOUSING

1. Install transmission holding fixture, as shown in Figure 26, that will allow you to rotate the transmission. 2. Remove the input shaft from transmission, as shown in Figure 25.

3. Remove the output shaft speed sensor from the extension housing, as shown in Figure 27. 4. Remove and discard the output shaft speed sensor "O" ring, as shown in Figure 27.


TRANSMISSIONHOLDING FIXTURE

RF3C3P-7006-AE

FordFord

98

3C3P-7000-KB F5A4522 180302

DDMMYYPDT-25

A1F5

Continued on Page 27

FordFord



27



RETAININGBOLT

"O" RING

TURBINE/INTERMEDIATESHAFT SPEED SENSOR

Figure 28

(1)

(2)

(3)

(4)


Speed Sensor

Gray/Orange

Green/White

Pink/White

Black/White



TSS Sig

Grnd

Ref Volt

ISS Sig





Pink/White(1)

(2)

(3)Black/White

Blue/Yellow


Grnd

Ref Volt

OSS Sig



Figure 30

Figure 29

TRANSMISSION DISASSEMBLYEXTERNAL COMPONENTS

5. Remove the turbine shaft/intermediate shaft speed sensor from the transmission case, as shown in Figure 28. 6. Remove and discard the turbine/intermediate speed sensor "O" ring, as shown in Figure 28. 7. Check both speed sensors for the proper ohms readings using Figure 29 and 30. 8. Replace the speed sensors as necessary.





TRANSMISSION DISASSEMBLYINTERNAL COMPONENTS

9. Rotate the transmission so that the bottom pan is facing up, as shown in Figure 31. 10. Remove the twenty oil pan bolts, as shown in Figure 31, and remove the oil pan.


28

FLUID PAN BOLTS(20 REQUIRED)

PAN

ISEQ

UIPP

EDW

ITH

ARE

USAB

LEGA

SKET

FordFord



28


Figure 31



29


FLUID FILTER

FLUID PAN GASKET(REUSABLE)

DISCONNECT THE TRANSMISSIONRANGE SENSOR CONNECTOR

FILTER SEAL

Figure 32

TRANSMISSION DISASSEMBLYINTERNAL COMPONENTS (CONT'D)

11. Remove and discard the fluid filter and filter seal, as shown in Figure 32. 12. Disconnect Transmission Range Sensor (TRS) connector from the range sensor, as shown in Figure 32.

13. Remove the pan gasket from the transmission case, as shown in Figure 32. Note: The pan gasket is reusable as long as none of the beads are broken.


Sol. Body toChan. Plate

(3)(27mm)

8 mmHead

8 mmHead

9.8 9.8

Sol. Bodyto Case

(3)(42mm) Sol. Body

to Chan. Plate(1)

(55mm)

8 mmHead

8 mmHead

9.8 9.8

Sol. Bodyto Case

(13)(67.5mm)

8 mmHead

9.8

WireHarness

(2)(15.5mm)

30 TorxHead

"A" "B" "C" "D" "E" "F" "G"

ReinforcingPlate to

Chan. Plate(5)

(16mm) ReinforcingPlate to Case

(5)(30mm)

8 mmHead

9.8

5R110W (Torqueshift) VALVE BODY BOLT CHART


PC-A

TCC

SSPC-B

SSPC-C

SSPC-E

SSPC-D

SSPC-A

A

A

A

A

C

C

C

C

CA

F F D B

B

B

D

G

G

D

E

FF

F

F

F

F

F F

F

F

F



30


Figure 33



31


SOLENOID BODY ANDCHANNEL PLATE

ASSEMBLY

SOLENOID BODYTO CASE (67.5MM)

(13 REQUIRED)

SOLENOID BODYTO CASE (42 MM)

(3 REQUIRED)REINFORCING PLATE

TO CASE (30 MM)(5 REQUIRED)


14. Remove only the valve body bolts not shaded in Figure 33, which are the bolts that retain the valve body to the case, as shown in Figure 34. 15. Remove the valve body from the case using a slight twisting motion to remove the main case connector from the case bore (See Figure 34).

16. Set the complete valve body and channel plate assembly aside for component rebuild section.


Figure 34



32


FORWARDCLUTCHORIFICE

CHANNEL PLATETO CASE GASKET

Figure 35


17. Remove and discard the channel plate to case gasket, as shown in Figure 35. 18. Remove the forward clutch orifice from the case cavity, as shown in Figure 35. Note: Place forward clutch orifice in a place where it will not get lost.




33

Copyright © 2004 ATSGCopyright © 2004 ATSG


19. Remove the external manual lever retaining pin using a No. 51 (.037") drill bit, as shown in Figure 36, by tapping it with small hammer into roll pin, and removing pin with side cutters. 20. Remove the external manual shift lever from transmission case, as shown in Figure 36.

21. Remove the two TRS retaining bolts, as shown in Figure 37, and remove the transmission range sensor assembly and parking rod as an assembly (See Figure 37).


RETAINING BOLTS(2 REQUIRED)

EXTERNAL MANUALSHIFT LEVER

RETAININGPIN

NO. 51 (.037")DRILL BIT

FOR PIN REMOVAL

TRANSMISSIONRANGE SENSOR

ASSEMBLY

Figure 36 Figure 37



34



22. Remove and discard the two support feed bolts, as shown in Figure 38. Note: The feed bolts will not retain torque specification if they are reused. 23. Rotate transmission in fixture so that the bell housing is facing up, as shown in Figure 39. 24. Remove the nine oil pump to case retaining bolts, as shown in Figure 39. 25. Remove the oil pump assembly using slide hammer as necessary (See Figure 39). 26. Remove and discard oil pump to case gasket, as shown in Figure 39.


Figure 38 Figure 39

INTERMEDIATE AND FORWARDCLUTCH FEED BOLTS

11

8

10

13

7KXV9.8

3C3R3C3R3C3R3C3R0701C0701C0701C0701C

KXV9.8

KXV9.8

KXV9.8

KXV9.8

KXV9.8

KXV9.8

KXV9.8

KXV9.8

7 OIL PUMP TO CASE RETAINING BOLTS (9 REQUIRED). 8 OIL PUMP ASSEMBLY. 10 PUMP TO COAST CLUTCH DRUM (NO 1) THRUST WASHER. 11 OIL PUMP TO CASE GASKET. 13 PUMP SUPPORT TO COAST CLUTCH (NO 2) THRUST BEARING.




35


HH

HH

HH

1617

20

18

19

16 OVERDRIVE CLUTCH FRICTION PLATES (3 REQUIRED). 17 OVERDRIVE CLUTCH STEEL PLATES (3 REQUIRED). 18 OVERDRIVE CLUTCH BACKING PLATE. 19 OVERDRIVE CLUTCH BACKING PLATE SNAP RING. 20 COAST CLUTCH HOUSING ASSEMBLY.


27. Remove the pump support to coast clutch drum (No. 1) thrust washer (See Figure 39). 28. Remove the pump support to coast clutch drum (No. 2) thrust bearing (See Figure 39). Note: Both thrust washer and bearing may be stuck to back of pump support. 29. Remove the overdrive steel and lined plates, as shown in Figure 40. 30. Remove the coast clutch housing assembly, by lifting straight up, as shown in Figure 40. 31. Set the coast clutch housing assembly aside for the component rebuild section. 32. Remove the overdrive clutch backing plate, as shown in Figure 40. 33. Remove the overdrive clutch backing plate snap ring from case groove and remove from transmission, as shown in Figure 40.


Figure 40



36

9.89.8KXVKXV

9.8KXV

9.8KXV

Copyright © 2004 ATSG Copyright © 2004 ATSG


35. Remove the number 4 thrust bearing, as shown in Figure 41. Note: Bearing may be stuck to back side of the overdrive carrier. 36. Remove the overdrive ring gear and center shaft, as shown in Figure 41. 37. Remove the number 5 thrust bearing, as shown in Figure 41. Note: Bearing may be stuck to back side of center shaft and ring gear assembly. 38. Remove the retaining snap ring from the case groove and remove the center support assembly from case, as shown in Figure 42. Note: Thrust washer may be stuck to back side of center support. 39. Set the center support assembly aside for the component rebuild section.


Figure 41 Figure 42

30 COAST CLUTCH HUB AND OVERDRIVE CARRIER ASSEMBLY 32 NUMBER 4 THRUST BEARING ASSEMBLY 33 OVERDRIVE RING GEAR AND CENTER SHAFT ASSEMBLY 36 NUMBER 5 THRUST BEARING ASSEMBLY

30

32

33

36

CENTER SUPPORTSNAP RING

CENTER SUPPORTASSEMBLY

NUMBER 6THRUST WASHER

34. Remove the coast clutch hub and overdrive carrier assembly, as shown in Figure 41, by lifting straight up. Note: "PTO" version illustrated in Figure 41.



37



40. Remove the intermediate clutch plates and the intermediate clutch backing plate, as shown in Figure 43. 41. Remove the direct clutch housing assembly, as shown in Figure 44, and set housing aside for the component rebuild section. 42. Remove the forward clutch housing assembly, as shown in Figure 44, and set housing aside for the component rebuild section.

43. The number 7 thrust washer and the number 8 thrust bearing should remain with the forward clutch housing.


46 INTERMEDIATE CLUTCH FRICTION PLATES 47 INTERMEDIATE CLUTCH STEEL PLATES 48 INTERMEDIATE CLUTCH BACKING PLATE

49 DIRECT CLUTCH HOUSING, COMPLETE 58 NUMBER 7 THRUST WASHER 59 NUMBER 8 THRUST BEARING 61 FORWARD CLUTCH HOUSING, COMPLETE

46

47

48 61

58

59

49

Figure 43 Figure 44


44. Remove the forward ring gear and number 10 thrust washer, as shown in Figure 45. 45. Remove the forward planetary carrier assembly and the number 11 thrust bearing, as shown in Figure 45. 46. Remove the carrier to sun gear shell assembly number 12 thrust bearing (See Figure 45) 47. Remove the sun gear and shell assembly, as shown in Figure 46.


69 FORWARD RING GEAR NUMBER 10 THRUST WASHER 71 PLANET CARRIER TO SUN GEAR NUMBER 12 THRUST BEARING 73 FORWARD INTERNAL RING GEAR ASSEMBLY 74 RING GEAR TO CARRIER NUMBER 11 THRUST BEARING 75 FORWARD PLANETARY CARRIER ASSEMBLY



38


71

75

74

73

69

SUN GEAR ANDSHELL ASSEMBLY

Figure 45 Figure 46



39



48. Remove the low diode retaining snap ring from the case groove (See Figure 47). 49. Remove the low diode, low/reverse clutch pack and rear planetary carrier as an assembly, as shown in Figure 47. 50. Remove the rear carrier to rear ring gear thrust bearing (Number 15), as shown in Figure 47. 51. Remove the rear planetary ring gear assembly and the number 16 thrust bearing, as shown in Figure 47. 52. Rotate the transmission in holding fixture so extension housing is facing up, as shown in Figure 48. Note: 4WD version is shown. 53. Using the special socket 307-458, as shown in Figure 48, loosen the output shaft nut on the 4WD version.


S I D ESI UH PT

S I D ESI UH PT

82

71 NUMBER 15 THRUST BEARING ASSEMBLY 82 LOW DIODE RETAINING SNAP RING 86 LOW DIODE, L/R CLUTCHES, REAR PLANETARY CARRIER 88 REAR PLANETARY CARRIER INTERNAL RING GEAR 91 NUMBER 16 THRUST BEARING ASSEMBLY

88

91

71

86

Figure 47 Figure 48

OUTPUT SHAFTNUT DRIVER(307-458)


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54. Remove the output shaft nut from the output shaft, as shown in Figure 49. 55. Remove the nine bolts retaining the extension housing, as shown in Figure 50. 56. Remove the extension housing, as shown in Figure 50, and set aside for component rebuild section. 57. Remove and discard extension housing gasket, as shown in Figure 50.



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Figure 50Figure 49


OUTPUT SHAFTNUT

"4WD VERSION"


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"4WD VERSION"

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EXTENSION HOUSINGRETAINING BOLTS

EXTENSIONHOUSING

EXTENSIONHOUSING GASKET

OUTPUTSHAFT



41

Figure 51 Figure 52



58. Remove the output shaft from transmission, as shown in Figure 51. 59. Remove the No. 17 thrust bearing, as shown in Figure 51.

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SPEED SENSORROTOR ANDPARK GEAR

OUTPUTSHAFT

NUMBER 17THRUST BEARING

LUBEORIFICE

LUBEORIFICE


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OUTPUTSHAFT



SOME MODELS USETHRUST WASHER



60. The 2WD version is shown in Figure 52, which is basically the same as the 4WD version. Note: Some models use a Number 17 thrust washer between park gear and case instead of a thrust bearing. 61. Remove the park rod guide plate, parking pawl, park pawl pivot pin and return spring, as shown in Figure 53. 62. Rotate the transmission in fixture so that bell housing is facing up, as shown in Figure 54. 63. Using a suitable spring compressor, compress the low/reverse clutch piston return spring and remove the snap ring (See Figure 54).



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Figure 53

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Figure 54

RETAININGBOLTS

PARK PAWL,PIVOT PIN,

AND RETURNSPRING

PARK RODGUIDE PLATE

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64. Remove the low/reverse clutch piston return spring assembly, as shown in Figure 54. 65. Remove the low/reverse clutch apply piston, as shown in Figure 54.


94

93

92

92 LOW/REVERSE CLUTCH RETURN SPRING SNAP RING 93 LOW/REVERSE CLUTCH RETURN SPRING ASSEMBLY 94 LOW/REVERSE CLUTCH PISTON



43

COMPONENT REBUILDTRANSMISSION CASE

1. Inspect all case parts thoroughly for any wear and/or damage. Repair or replace as necessary. 2. Clean all case parts thoroughly and dry with compressed air. 3. Remove and discard the case linkage seal. 4. Using the proper seal driver, install a new case linkage seal, and lubricate with a small amount of Trans-Jel®. 5. Install two new scarf-cut Teflon® seals into the seal retainer in back of case just below the rear case bushing, as shown in Figure 55. 6. Lubricate the two seals with a small amount of Trans-Jel®. 7. Lube the seals on a new low/reverse molded piston and install piston into case, as shown in Figure 56.

Figure 55 Figure 56

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TEFLON® SEALRETAINER


94

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92 LOW/REVERSE CLUTCH RETURN SPRING SNAP RING 93 LOW/REVERSE CLUTCH RETURN SPRING ASSEMBLY 94 LOW/REVERSE CLUTCH PISTON

8. Install the low/reverse piston return spring, as shown in Figure 56. 9. Compress the return spring with appropriate spring compressor and install snap ring. 10. Ensure that snap ring is fully seated in the case groove.




44


EXTERNAL MANUALSHIFT LEVER

CASERETAINING

PIN

SENSORRETAINING

PIN


RETAINING BOLTS(2 REQUIRED)

TRANSMISSIONRANGE SENSOR

ASSEMBLY

COMPONENT REBUILDTRANSMISSION CASE (Cont'd)

11. Rotate the case with pan surface facing up and install the park rod, inside detent lever and the transmission range sensor (See Figure 57). 12. Install the two range sensor retaining bolts, but do not tighten. 13. Install the external manual shift lever through the case and into the range sensor, as shown in Figure 58, and install case retaining pin. 14. Rotate the shift lever to align with hole in the range sensor and install new sensor retaining pin, as shown in Figure 59. Note: Leave 1/16 inch of pin exposed.


Figure 57

Figure 58

Figure 59



45

COMPONENT REBUILDTRANSMISSION CASE (Cont'd)


15. Torque the transmission range sensor retaining bolts to 10 N•m (89 in.lb.) (See Figure 60). 16. Rotate transmission in fixture so that the rear surface is facing up, as shown in Figure 61. 17. Install the parking pawl, pivot pin and return spring, as shown in Figure 61, and ensure that return spring is hooked properly behind case. 18. Install the parking rod guide plate, as shown in Figure 61. 19. Install the two park rod guide plate retaining bolts and torque to 24 N•m (18 ft.lb.). Note: Ensure that park rod operates freely through the guide plate. 20. Install the number 17 thrust bearing onto the case, in the direction shown in Figure 62, and retain with a small amount of Trans-Jel®. Note: Some models use a Number 17 thrust "washer" between case and park gear instead of a thrust bearing.



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PARK PAWL,PIVOT PIN,

AND RETURNSPRING

PARK RODGUIDE PLATE

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Figure 61

Figure 62Figure 60


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TRANSMISSION CASE (Cont'd)


21. Remove and inspect park gear/speed sensor rotor, as shown in Figure 63, and replace as necessary. 22. Install the output shaft and park gear assembly into the transmission, as shown in Figure 64.



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"4WD VERSION""4WD VERSION"

"2WD VERSION"


SPEED SENSOR ROTORAND PARK GEAR ARE

INSTALLED WITH A"LIGHT" PRESS FIT

OUTPUTSHAFT



Figure 63 Figure 64

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Figure 67Figure 66


RETURN SPRINGIS HOOKED ON

CASE

RETURN SPRINGIS HOOKED ON

CASE

ENSURE THATPARK ROD

TRAVELS FREELY

ENSURE THATPARK ROD

TRAVELS FREELY

THIS TORX HEAD BOLTMUST BE DISCARDED ANDREPLACED, IF REMOVED

THIS TORX HEAD BOLTMUST BE DISCARDED ANDREPLACED, IF REMOVED



23. Install a new lube orifice plug in the case, as shown in Figure 65. 24. Before installing extension housing, ensure that park pawl return spring is hooked behind the case, and park rod operates freely through the guide plate (See Figure 66). 25. The Torx head bolt retaining the parking pawl abutment plate, shown in Figure 66, has thread locking compound and should not be removed unless damage is apparent. Note: If it was removed, Ford recommends that it be discarded and a new bolt installed and torqued to 16-27 N•m (12-20 ft.lb.). 26. Install new extension housing seal using the proper seal driver (See Figure 67). Note: 4WD version is shown, 2WD similiar. 27. Replace the ball bearing in the 4WD version as necessary using the proper drivers. Refer to Figure 67.

"4WD VERSION"

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LUBE ORIFICEPLUG


Figure 65



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EXTENSIONHOUSING

EXTENSIONHOUSING GASKET

OUTPUTSHAFT

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Figure 69Figure 68



28. Install new extension housing gasket onto the transmission, as shown in Figure 68. 29. Install the completed extension housing onto the transmission, as shown in Figure 68. 30. Install the extension housing retaining bolts, as shown in Figure 68. 31. Torque all of the extension housing bolts to 47 N•m (35 ft.lb.), as shown in Figure 69.

TORQUE EXTENSION HOUSINGBOLTS TO 47 N•m (35 ft.lb.)



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Figure 71

Figure 70

Figure 72


"O" RING

OUTPUT SHAFTNUT

OUTPUT SHAFTNUT GROOVE

"4WD VERSION"


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COMPONENT REBUILDContinued on Page 50

32. Install new "O" ring into the groove in output shaft nut, as shown in Figure 70, and lube with a small amount of Trans-Jel®. 33. Install the output shaft nut onto output shaft, using the special nut driver 307-458, as shown in Figure 71, and hand tighten. 34. Torque the output shaft nut, using 1/2" drive torque wrench, to 200 N•m (148 ft.lb.), as shown in Figure 72. 35. Transmission case is now ready for the final assembly process. Rotate the transmission so that bell housing is facing up.

TORQUE OUTPUT SHAFT NUTTO 200 N•m (148 ft.lb.)



50


REINFORCING PLATETO CHANNEL PLATE

(16 MM) (5 REQUIRED)

SOLENOID BODYTO CHANNEL PLATE




WIRE HARNESS15.5 MM

(2 REQUIRED)

REINFORCINGPLATE

REINFORCINGPLATE GASKET

CHANNEL PLATE

SOLENOIDBODY GASKET

SOLENOID BODYASSEMBLY



Figure 73

1. Remove the 4 bolts that retain the solenoid body to the channel plate and one bolt into the channel plate for internal wiring harness, as shown in Figure 73.

2. Remove the 5 bolts holding the reinforcing plate to the channel plate and discard gasket, as shown in Figure 73.

COMPONENT REBUILDSOLENOID BODY ASSEMBLY


PC-A

TCC

SSPC-B

SSPC-C

SSPC-E

SSPC-D

SSPC-A



51


7 DIRECT CLUTCH SOLENOID, SSPC-"D" (INVERSE) 8 INTERMEDIATE CLUTCH SOLENOID, SSPC-"C" (DIRECT) 9 SOLENOID RETAINING "E" CLIP (7 REQUIRED) 10 MANUAL SHIFT VALVE 11 PRESSURE SWITCH ASSEMBLY 12 PRESSURE SWITCH ASSEMBLY RETAINING CLIP

1 SOLENOID BODY CASTING 2 COAST CLUTCH SOLENOID, SSPC-"A" (INVERSE) 3 OVERDRIVE CLUTCH SOLENOID, SSPC-"B" (DIRECT) 4 TORQUE CONVERTER CLUTCH SOLENOID, TCC (DIRECT) 5 PRESSURE CONTROL SOLENOID, PC-"A" (INVERSE) 6 LOW/REVERSE CLUTCH SOLENOID, SSPC-"E" (DIRECT)

Figure 74

SOLENOID BODY ASSEMBLY EXPLODED VIEW

3C 383 3P7GCA

3C 383 3P7GBA

3C 383 3P7GBA

3C 383 3P7GCA

3C 383 3P7GBA

3C 383 3P7GBA

1

11

11

11

11

11

TOT SENSOR

12

2

3C 383 3P7GCA

3

4

5

6

9

9

9

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9

9

9

7

8

10



52


3C 383 3P7GCA

3C 383 3P7GBA

TCC, SSPC-B, SSPC-C, SSPC-E"Directly" Proportional Solenoids


PC-A, SSPC-A, SSPC-D"Inversely" Proportional Solenoids


Retaining"E" Clip

Retaining"E" Clip

LocatingTabs "High" Locating

Tabs "Low"

Rear View Rear ViewFront View Front View

Figure 75


3. Disassemble the solenoid body assembly, as shown in Figure 74. 4. If it becomes necessary to replace the internal wire harness and/or the entire solenoid body on a 5R110W Torqshift transmission, please be aware of the following: A. You may have to install a new Ford service harness, without switch connectors, into a unit that has pressure switches. B. You may have to install a new Ford service solenoid body, without pressure switches into a unit that has the original harness with switch connectors (See Figure 74 for locations).

7. Install the solenoids in their proper locations exactly as shown in Figure 74. Note: Solenoids can be tested for the proper resistance using the chart in Figure 16. 8. Install the retaining "E" clip on each one of the solenoids, as shown in Figure 74. 9. Install new seals on each pressure switch to ensure no leakage, even if there are no wire connectors on the harness (See Figure 76). 10. Install the internal wire harness through the hole in the solenoid body and lock into place with a twisting motion (See Figure 77). 11. Install each of the connectors in their proper locations and ensure they are fully seated and locked (See Figure 77). 12. Install the manual shift valve in the direction shown in Figure 74. 13. Install new "O" ring seal in upper most groove of the internal wire harness case connector, as shown in Figure 78, and lubricate with a small amount of Trans-Jel®.


Note: These are both acceptable repairs and will not affect the function or operation of the transmission. Use of the pressure switch input was dropped from the vehicle calibration before the 2003 model year went into production.

5. Clean all solenoid body parts thoroughly with cleaning solution and dry with compressed air. 6. Notice that the solenoids have locating tabs that are in different locations, to prevent you from installing them in the wrong locations. Refer to Figure 74 and 75 for identification of the different solenoids.

WIRE HARNESS TOSOLENOID BODY BOLT

ENSURE THAT WIREHARNESS CONNECTORIS LOCKED INTO PLACE

INSTALL "O" RING INTOUPPER MOST GROOVE



53





Retaining Clip

PressureSwitch

Boot/Seal

Top View

Figure 76

Figure 78

Figure 77


"O" RING SEAL



54



14. Install new reinforcing plate gasket on channel plate, as shown in Figure 79. 15. Install reinforcing plate and 5 bolts, as shown in Figure 79, and hand tighten only. 16. Install new solenoid body to channel plate screen/gasket, as shown in Figure 79. 17. Install the previously completed solenoid body assembly, as shown in Figure 79.

18. Install the 4 solenoid body to channel plate bolts in the locations shown in Figure 79, and hand tighten only at this time. 19. Install the wire harness to channel plate bolts as shown in Figure 79. 20. Set the completed solenoid body aside for the final assembly process (See Figure 80).

REINFORCING PLATETO CHANNEL PLATE


REINFORCINGPLATE

REINFORCINGPLATE GASKET

CHANNEL PLATE

SOLENOID BODYSCREEN/GASKET





WIRE HARNESS15.5 MM

(2 REQUIRED)

SOLENOID BODYASSEMBLY



Figure 79




55



"COMPLETED"SOLENOID BODY AND

CHANNEL PLATEASSEMBLY

Figure 80

If it becomes necessary to replace the internal wire harness and/or the entire solenoid body on a 5R110W Torqshift transmission, please be aware of the following: 1. You may have to install a new service harness, without pressure switch connectors, into a unit with the pressure switches in the solenoid body. (See Figure 74 for locations) 2. You may have to install a new service solenoid body, without pressure switches, into a unit that has the original internal harness with pressure switch connectors. (See Figure 74 for locations)

Note: These are both acceptable repairs and will not affect the function or operation of the transmission. Use of the pressure switch input was dropped from the vehicle calibration before the 2003 model year went into production.

INTERNAL HARNESS OR SOLENOID BODY SERVICE

3C

3R

3C

3R

3C

3R

3C

3R

070

1C0

70

1C0

70

1C0

70

1C

FRONT PUMP EXPLODED VIEW

1

2

34

5

6

7

8

9

10

11

11

12 13



56


1 FRONT PUMP CONVERTER SEAL. 2 FRONT PUMP CONVERTER HUB BUSHING. 3 FRONT PUMP BODY. 4 OIL PUMP TO CASE "D" RING SEAL. 5 OIL PUMP INNER GEROTOR. 6 OIL PUMP OUTER GEROTOR. 7 OIL PUMP WEAR PLATE. 8 STATOR SHAFT OIL SEAL. 9 OIL PUMP COVER ASSEMBLY. 10 COAST CLUTCH SEALING RINGS (2 REQUIRED). 11 OIL PUMP COVER TO BODY BOLTS (8 REQUIRED). 12 OD CLUTCH MOLDED PISTON ASSEMBLY. 13 OD CLUTCH PISTON RETURN SPRING ASSEMBLY.

Figure 81

1 FRONT PUMP CONVERTER SEAL. 2 FRONT PUMP CONVERTER HUB BUSHING. 3 FRONT PUMP BODY.

3 FRONT PUMP BODY. 5 OIL PUMP INNER GEROTOR. 6 OIL PUMP OUTER GEROTOR.

3C3R3C3R3C3R3C3R0701C0701C0701C0701C



57



1

2

3

3

5

6

1. Disassemble the oil pump assembly using Figure 81 as a guide. 2. Remove and discard the converter seal, pump body "O" ring, and sealing rings. 3. Inspect all oil pump parts thoroughly for any wear and/or damage, replace as necessary. 4. Clean all oil pump parts thoroughly and dry with compressed air. 5. Inspect the pump body bushing and replace as necessary, as shown in Figure 82, using the proper driver. 6. Install a new oil pump converter seal using the proper driver, as shown in Figure 82. 7. Lubricate the oil pump gears with fluid and install them into the pump body pocket with marks facing up, as shown in Figure 83. 8. Measure the gear to face clearance with the depth micrometer, as shown in Figure 84. 9. Proper clearance should be: .04-.06 mm (.0015"-.0023") (See Figure 84).

COMPONENT REBUILDOIL PUMP ASSEMBLY

Figure 84

Figure 83

Figure 82

MarksFacing Up


DEPTHMICROMETER

S tttarre

98 0

Gear To Face Clearance.04 - .06 mm (.0015" - .0023")


Snap-On



58



COAST CLUTCHSEAL RINGS

STATOR SHAFTASSEMBLY

RETAININGBOLTS (3 REQ)

OIL PUMPCOVER

TORQUE TO 9-11 N·M (80-100 IN.LB.)


OIL PUMPWEAR PLATE

ALIGNMENTDOWELS

10. Install 2 alignment dowels made from spare bolts in pump body, as shown in Figure 85. 11. Install the oil pump wear plate over the dowels, as shown in Figure 85. 12. It is not necessary to remove the stator shaft from pump cover unless damage is apparent. 13. If it was removed, install the stator shaft and torque the bolts to 9-11 N•m (80-100 in.lb.) as shown in Figure 86 and 87. 14. Install 2 new coast clutch scarf-cut seal rings onto the stator shaft, as shown in Figure 87. 15. Install the valves, springs, bore plugs and the retainers, exactly as shown in Figure 88. Note: Retainer locations are also shown in Figure 88. 16. Prior to installation, lubricate valves and bore plugs with transmission fluid.

COMPONENT REBUILDOIL PUMP ASSEMBLY (CONT'D)

Figure 85 Figure 87

Figure 86




59


1 CONVERTER CLUTCH CONTROL VALVE BORE PLUG RETAINER. 2 CONVERTER CLUTCH CONTROL VALVE SLEEVE. 3 CONVERTER CLUTCH CONTROL VALVE PLUG. 4 CONVERTER CLUTCH CONTROL VALVE SPRING. 5 CONVERTER CLUTCH CONTROL VALVE SPRING SEAT. 6 CONVERTER CLUTCH CONTROL VALVE. 7 COOLER BYPASS VALVE BORE PLUG RETAINER (ORANGE I.D.). 8 COOLER BYPASS VALVE BORE PLUG. 9 THERMOSTATIC VALVE ASSEMBLY. 10 COOLER BYPASS VALVE. 11 COOLER BYPASS VALVE SPRING. 12 CONVERTER PRESSURE LIMIT VALVE BORE PLUG RETAINER.

13 CONVERTER PRESSURE LIMIT VALVE BORE PLUG. 14 CONVERTER PRESSURE LIMIT VALVE SPRING. 15 CONVERTER PRESSURE LIMIT VALVE. 16 CONVERTER ANTI-DRAIN BACK VALVE BORE PLUG RETAINER. 17 CONVERTER ANTI-DRAIN BACK VALVE BORE PLUG. 18 CONVERTER ANTI-DRAIN BACK VALVE SPRING. 19 CONVERTER ANTI-DRAIN BACK VALVE. 20 MAIN REGULATOR VALVE BORE PLUG RETAINER. 21 MAIN REGULATOR VALVE BORE PLUG. 22 MAIN REGULATOR VALVE SPRING. 23 MAIN REGULATOR VALVE. 24 OIL PUMP COVER ASSEMBLY.

1

2

8

14

18

22

23

24

19

20

15 9

10

11

3

4

5

6

7

12

16

17

21

13

1

7

12

16

20

OIL PUMP COVER ASSEMBLY EXPLODED VIEW

Figure 88



60


ALIGNMENTDOWELS

COMPLETEDPUMP BODY

PUMP COVERASSEMBLY

9 OIL PUMP COVER ASSEMBLY. 11 OIL PUMP COVER TO BODY BOLTS (8 REQUIRED). 12 OD CLUTCH MOLDED PISTON ASSEMBLY.

9

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13Continued on Page 61

17. Install the completed pump cover assembly over the dowels, as shown in Figure 89. 18. Lubricate and install new overdrive clutch piston, as shown in Figure 90. 19. Install the overdrive clutch piston return spring assembly, as shown in Figure 90. 20. Install three return spring retaining bolts in the locations, shown in Figure 90, and tighten by hand only.


Figure 89 Figure 90

10 PUMP TO COAST CLUTCH DRUM (NO 1) THRUST WASHER. 13 PUMP SUPPORT TO COAST CLUTCH (NO 2) THRUST BEARING.


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TORQUE TO 31 N·M (23 FT.LB.)



61


21. Install the 5 remaining pump cover to pump body bolts in the locations shown in Figure 91 and hand tighten only. 22. Install and tighten the alignment strap around the pump body and cover (See Figure 92). 23. Torque all pump cover to pump body bolts to 31 N•m (23 ft.lb.) as shown in Figure 92. 24. Install the number 1 thrust washer, as shown in Figure 93, and retain with a small amount of Trans-Jel®. 25. Install the number 2 thrust bearing onto stator shaft, in the direction shown in Figure 93, and retain with a small amount of Trans-Jel®.


Figure 91 Figure 93

Figure 92

ALIGNMENTSTRAP

13

10

3C3R3C3R3C3R3C3R0701C0701C0701C0701C



62


COMPLETED OIL PUMP ASSEMBLY


3C3R3C3R3C3R3C3R0701C0701C0701C0701C

26. Install new pump to case "D" ring seal into the groove in pump body and ensure that it is not twisted (See Figure 94). 27. Install new Teflon® seal on stator shaft, as shown in Figure 94. 28. Set the completed oil pump assembly aside for the final assembly process (See Figure 95).


Figure 94

Figure 95

Component RebuildContinued on Page 63

TEFLON SEAL

"D" RING SEAL

Special Note: Start now pre-soaking all clutch friction plates in "Mercon® SP" fluid only, prior to any further assembly.

SID

EU

ISP

TH

COAST CLUTCH HOUSING EXPLODED VIEW

202122

23

24

252628

20 COAST CLUTCH HOUSING ASSEMBLY. 21 COAST CLUTCH MOLDED RUBBER, STAMPED STEEL PISTON ASSEMBLY. 22 COAST CLUTCH PISTON RETURN SPRING ASSEMBLY. 23 COAST CLUTCH RETURN SPRING ASSEMBLY SNAP RING. 24 COAST CLUTCH FRICTION PLATES (3 REQUIRED). 25 COAST CLUTCH STEEL PLATES (3 REQUIRED). 26 COAST CLUTCH BACKING PLATE/OVERDRIVE ONE-WAY CLUTCH DIODE ASSEMBLY. 28 COAST CLUTCH BACKING PLATE SNAP RING.



63


Figure 96

COMPONENT REBUILDCOAST CLUTCH HOUSING



64

COAST CLUTCHPISTONPISTON INSTALLER

307-387



1. Disassemble the coast clutch housing using Figure 96 as a guide. 2. Inspect all coast clutch parts thoroughly for any wear and/or damage. 3. Inspect coast clutch pressure plate which now incorporates the mechanical diode one way clutch, as shown in Figure 97. Note: Inside splines should freewheel in the direction shown in Figure 97, and lock in the opposite direction. 4. Clean all coast clutch parts thoroughly and dry with compressed air. 5. Lube and install a new coast clutch piston into the coast clutch housing using the installer, as shown in Figure 98. 6. Remove the seal installer. 7. Install the coast clutch piston return spring assembly, as shown in Figure 99. 8. Compress the return spring using the proper adapters and install the snap ring, as shown in Figure 99. 9. Ensure that snap ring is fully seated in the groove in coast clutch housing.

SIDE UIS PTH

Inside Splines Should FreewheelCounter-Clockwise And Lock Clockwise

While Holding External Splines

Must Be Visible WhenInstalled In Housing

Figure 97 Figure 99

Figure 98

20

22

23

20 COAST CLUTCH HOUSING ASSEMBLY. 22 COAST CLUTCH PISTON RETURN SPRING ASSEMBLY. 23 COAST CLUTCH RETURN SPRING ASSEMBLY SNAP RING.





65

SIDE UIS PTH

25

26

28

20

24

20 COAST CLUTCH HOUSING ASSEMBLY. 24 COAST CLUTCH FRICTION PLATES (3 REQUIRED). 25 COAST CLUTCH STEEL PLATES (3 REQUIRED). 26 COAST CLUTCH BACKING PLATE/ONE-WAY CLUTCH ASSEMBLY. 28 COAST CLUTCH BACKING PLATE SNAP RING.


SIDE UIS PTH

Coast Clutch Clearance Should Be0.76 - 1.27mm (.030" - .050")


COMPONENT REBUILDCOAST CLUTCH HOUSING (CONT'D)

10. Install the coast clutches beginning with a steel plate and alternating with friction plates until you have installed three of each, as shown in Figure 100. 11. Install the coast clutch backing plate and O.D. one-way clutch assembly, into the coast clutch housing in the direction shown in Figure 100. Note: The words "This Side Up" must be visible after installation (See Figure 97). 12. Install the coast clutch backing plate snap ring into the housing, as shown in Figure 100, and ensure that it is fully seated. 13. Turn the coast clutch drum over and tap against the work bench to seat the snap ring to the top of the groove. 14. Measure between the snap ring and the backing plate, as shown in Figure 101, with a feeler gauge to determine clutch clearance. 15. Proper coast clutch clearance should be: .76-1.27 mm (.030"-.050"). 16. Change the selective snap ring as necessary to obtain the proper coast clutch clearance. 17. Set the completed coast clutch housing aside for the final assembly process.

Figure 100 Figure 101

9.8

KX

V

9.8

KX

V

9.8

KX

V

9.8

KX

V

3533 34

31

32

29

30

28

28

36

28 COAST CLUTCH HUB TO O.D. CARRIER BOLT (4 REQUIRED) 29 COAST CLUTCH HUB, "NON-PTO" VERSION 30 COAST CLUTCH HUB, "PTO" VERSION 31 OVERDRIVE PLANETARY CARRIER ASSEMBLY 32 THRUST BEARING (NO. 4), CARRIER TO CENTER SHAFT 33 OVERDRIVE INTERNAL RING GEAR 34 CENTER SHAFT ASSEMBLY 35 CENTER SHAFT TO RING GEAR SNAP RING 36 THRUST BEARING (NO. 5), CENTER SHAFT TO CENTER SUPPORT

9.8

KX

V

9.8

KX

V

9.8

KX

V

9.8

KX

V



66


OVERDRIVE SECTION EXPLODED VIEW

Figure 102



67

9.8KXV

9.8KXV

9.8KXV

9.8KXV


"PTO" APPLICATIONS

COAST CLUTCHHUB ASSEMBLY

OVERDRIVEPLANETARYCARRIER


9.8KXV

9.8KXV

9.8KXV

9.8KXV


"NON-PTO" APPLICATIONS

COAST CLUTCHHUB ASSEMBLY

OVERDRIVEPLANETARYCARRIER


COMPONENT REBUILDOVERDRIVE SECTION


1. Disassemble the overdrive section parts using Figure 102 as a guide. Note: It is not necessary to remove the coast clutch hub assembly from the overdrive planetary carrier, unless damage is apparent. 2. Inspect all overdrive section parts thoroughly for any wear and/or damage. 3. Clean all overdrive parts thoroughly and dry with compressed air. Note: Do not spin the planetary pinions with air as damage may occur.

4. If it does become necessary to replace either overdrive planetary carrier or the coast clutch hub, remove the bolts as shown in Figure 103 and Figure 104. Note: These bolts "CANNOT" be reused because of the torquing procedure. They "MUST" be replaced with new bolts.


9.89.8KXVKXV

9.8KXV

9.8KXV



68




TORQUE SPECIFICATIONS

1. TORQUE EVENLY TO 30 N°M (22 FT.LB.)2. TIGHTEN AN ADDITIONAL 90 DEGREES

Figure 105

Figure 107Figure 106

COMPONENT REBUILDOVERDRIVE SECTION (CONT'D)

5. If it was necessary to replace the overdrive planetary carrier or the coast clutch hub, torque the new bolts as shown in Figure 105. Note: Do not over-torque or you will have to start again with more new bolts. 6. Set the coast clutch hub and overdrive carrier assembly onto a set of blocks, as shown in Figure 106. 7. Install the previously completed coast clutch housing onto the coast clutch hub, by rotating back and forth, to engage all friction plates on the hub and ensure it is fully seated. Refer to Figure 106. 8. Turn the entire assembly over and install the number 4 thrust bearing, in the direction shown in Figure 107, and retain with a small amount of Trans-Jel®.

9.89.8KXVKXV

9.8KXV

9.8KXV

COMPLETED COASTCLUTCH HOUSING

ASSEMBLY

COAST CLUTCH HUBOVERDRIVE CARRIER

ASSEMBLY

SUPPORTBLOCKS



ASSEMBLY TOOL307 S383

SUPPORTBLOCKS



69




36

35

34

33


COMPLETED OVERDRIVE RING GEARAND CENTER SHAFT ASSEMBLY

33 OVERDRIVE INTERNAL RING GEAR 34 CENTER SHAFT ASSEMBLY 35 CENTER SHAFT TO RING GEAR SNAP RING

COMPONENT REBUILDOVERDRIVE SECTION (CONT'D)

9. Turn the assembly over once again onto the set of blocks, as shown in Figure 108, and install the special installation tool 307-S383. 10. Tighten the special tool securely and set the assembly aside for the final assembly process. 11. It is not necessary to disassemble the internal ring gear and hub assembly, unless damage is apparent. 12. If replacement parts were needed at this time, use Figure 109 for assembly and disassembly of the ring gear and hub. 13. Set the overdrive ring gear and hub assembly aside for the final assembly process.



70


CENTER SUPPORT EXPLODED VIEW

4142

4344

45

38

38 CENTER SUPPORT ASSEMBLY 41 DIRECT CLUTCH TEFLON® SEALING RINGS (2 REQUIRED) 42 NUMBER 6 THRUST WASHER 43 INTERMEDIATE CLUTCH MOLDED PISTON 44 INTERMEDIATE CLUTCH PISTON RETURN SPRNG ASSEMBLY 45 INTERMEDIATE CLUTCH RETURN SPRING SNAP RING

Figure 110



71


38 CENTER SUPPORT ASSEMBLY 44 INTERMEDIATE CLUTCH PISTON RETURN SPRNG ASSEMBLY 38 CENTER SUPPORT ASSEMBLY

43 INTERMEDIATE CLUTCH MOLDED PISTON

38 38

44

45

43

COMPONENT REBUILDCENTER SUPPORT ASSEMBLY


1. Disassemble the center support assembly using Figure 110 as a guide. 2. Inspect all center support parts thoroughly for any wear and/or damage. 3. Clean all center support parts thoroughly and dry with compressed air. 4. Set center support on a flat work surface, as shown in Figure 111. 5. Lubricate new intermediate clutch piston seals with a small amount of Trans-Jel®.

6. Install the intermediate clutch piston into the center support, as shown in Figure 111. 7. Install the intermediate clutch piston return spring in direction shown in Figure 112. 8. Compress the return spring using appropriate spring compressor and install snap ring. 9. Ensure that snap ring is fully seated in groove.




72



38

38

42

41

UNIQUE"LAP" JOINT

UNIQUE"LAP" JOINT

38 CENTER SUPPORT ASSEMBLY 42 NUMBER 6 THRUST WASHER

38 CENTER SUPPORT ASSEMBLY 41 DIRECT CLUTCH TEFLON® SEALING RINGS (2 REQUIRED)

COMPLETED CENTER SUPPORT ASSEMBLY


Figure 114

COMPONENT REBUILDCENTER SUPPORT ASSEMBLY

10. Install the number 6 thrust washer onto the center support, as shown in Figure 113, and retain with a small amount of Trans-Jel®. 11. Install new direct clutch sealing rings into the grooves in the center support (See Figure 114). 12. Notice that the rings have a "unique" lap joint, as shown in Figure 114, and will require some special attention, to ensure that they engage properly. 13. Set the completed center support assembly, as shown in Figure 115, aside for final assemby.




73


Figure 116

INTERMEDIATE CLUTCH EXPLODED VIEW37 38

42 41

46A

46B

4847

2003-2004 Models24 Tooth

2005-Up Models96 Tooth

37 CENTER SUPPORT RETAINING SNAP RING 38 COMPLETE CENTER SUPPORT ASSEMBLY 41 DIRECT CLUTCH TEFLON® SEALING RINGS (2 REQUIRED) 42 NUMBER 6 THRUST WASHER

46A 2003-2004 INTERMEDIATE FRICTION PLATES (24 TOOTH) 46B 2005-UP INTERMEDIATE FRICTION PLATES (96 TOOTH) 47 INTERMEDIATE CLUTCH STEEL PLATES (ALL MODELS) 48 INTERMEDIATE CLUTCH BACKING PLATE (ALL MODELS)

INTERMEDIATE CLUTCH PLATES

1. Inspect intermediate clutch plates and ensure that you have the proper plates in your kit. Note: Beginning at start of production for 2005 models, the tooth count on the friction plates changed from 24 to 96, as shown in Figure 116. This also changes the direct clutch housing, which we will show later.

Note: Beginning at start of production for2005 models, the tooth count on the frictionplates changed from 24 to 96, as shownhere. This also changes the direct clutchhousing, which is shown on Page 82.

2. Set the "Proper" intermediate clutch friction plates, steel plates and backing plate aside for the final assembly process.




74


FORWARD CLUTCH HOUSING EXPLODED VIEW

68

65

64 63 62

61

5655

67

66

61

60

5859

55 FORWARD CLUTCH STEEL PLATES (4) 56 FORWARD CLUTCH BACKING PLATE 58 FORWARD CLUTCH NUMBER 7 THRUST WASHER 59 FORWARD CLUTCH NUMBER 8 THRUST BEARING 60 FORWARD CLUTCH SEALING RINGS (2) 61 FORWARD CLUTCH HOUSING ASSEMBLY 62 FORWARD CLUTCH APPLY PISTON 63 FORWARD CLUTCH "BELLVILLE" RETURN SPRING 64 FORWARD CLUTCH BALANCE PISTON 65 FORWARD CLUTCH RETURN SPRING SNAP RING 66 FORWARD CLUTCH "WAVE" PLATE 67 FORWARD CLUTCH FRICTION PLATES 68 FORWARD CLUTCH BACKING PLATE SNAP RING (SELECTIVE)

Figure 117



75


COMPONENT REBUILDFORWARD CLUTCH HOUSING

FORWARD CLUTCH HOUSING DIFFERENCES

FORWARD CLUTCH STEEL PLATES

FORWARD CLUTCH FRICTION PLATES

1. Disassemble the forward clutch housing using Figure 117 as a guide. 2. Inspect all forward clutch parts thoroughly for any wear and/or damage. 3. Clean all forward clutch parts thoroughly and dry with compressed air.

NOTICE: At start of production for 2005 models, Ford Motor Co. increased the diameter of the forward planetary carrier, increased pinion height, and larger pinion pins for increased durability.This required changes in the forward clutch housing components and are as follows. 1. Increased inside and pilot diameters of the forward clutch steel plates, as shown in Figure 118. 2. Increased inside and outside diameters of the forward clutch friction plates, as shown in Figure 119, which changes the tooth count.

Figure 119

Figure 118

2005-Up Models76 Tooth

Larger InsideDiameter

Approx.5.372"

Approx.5.117"

2003-2004 Models90 Tooth

2003-2004 Models

2003-2004 Models

2005-Up Models

2005-Up Models

Forward Clutch Housing DifferencesContinued on Page 76

Forward ClutchContinued on Page 77

Approx.6.372"

Approx.6.372"

Approx.6.250"

PilotDiameter

PilotDiameter

Approx.6.250"


FORWARD CLUTCH INTERNAL RING GEAR2003-2004 Models 2005-Up Models


FORWARD CLUTCH BACKING PLATE

2003-2004 Models 2005-Up Models



76

FORWARD CLUTCH HOUSING DIFFERENCES (CONT'D)

NOTICE: Continued from Page 75: 3. Increased inside and pilot diameters of the forward clutch backing plate, as shown in Figure 120. 4. Forward clutch internal ring gear increases in diameter, and the tooth count changes to accommodate the new friction plates, as shown in Figure 121. 5. The number 9 thrust washer changes to accommodate the new ring gear, as shown in Figure 121.

6. The forward clutch housing also changes with increased diameter lube holes in the hub for the direct clutch plates (See Figure 122).

Figure 120

Figure 121

Larger InsideDiameter

LargerDiameter

Approx.5.372"

Approx.5.117"



Approx.6.372"

PilotDiameter

PilotDiameter

Approx.6.250"



77



FORWARD CLUTCH HOUSING2003-2004 Models 2005-Up Models

Figure 122

Figure 123

LargerLubeHoles

61 FORWARD CLUTCH HOUSING ASSEMBLY 62 FORWARD CLUTCH APPLY PISTON

61

62

COMPONENT REBUILDFORWARD CLUTCH HOUSING (CONT'D)

4. Place the forward clutch housing on flat work surface, as shown in Figure 123. Note: Ensure that you have all of the correct forward clutch parts for the model that you are rebuilding, using the descriptions found in "Forward Clutch Differences". 5. Lubricate both inner and outer seal surfaces on forward clutch piston with Trans-Jel®. 6. Install the forward clutch piston into forward clutch housing, as show in Figure 123, using a slight twisting motion.


63 FORWARD CLUTCH "BELLVILLE" RETURN SPRING 64 FORWARD CLUTCH BALANCE PISTON 65 FORWARD CLUTCH RETURN SPRING SNAP RING

63

64

65

FORWARD CLUTCH HOUSING (CONT'D)

7. Install forward clutch piston return "Bellville" spring on top of the forward clutch piston in the direction shown in Figure 124. 8. Lubricate the seal and install the forward clutch balance piston, as shown in Figure 124. 9. Compress the return spring and balance piston and install snap ring (See Figure 124). Note: This operation requires hydraulic press. 10. Install the forward clutch "Wave" plate, as shown in Figure 125. 11. Install 4 steel plates and 4 friction plates for the model you're building, as shown in Figure 125.




78


55 FORWARD CLUTCH STEEL PLATES (4) 56 FORWARD CLUTCH BACKING PLATE 61 FORWARD CLUTCH HOUSING ASSEMBLY 66 FORWARD CLUTCH "WAVE" PLATE 67 FORWARD CLUTCH FRICTION PLATES 68 FORWARD CLUTCH BACKING PLATE SNAP RING (SELECTIVE)

61

66

56

68

67

55



12. Install the forward clutch backing plate and the selective snap ring, as shown in Figure 125. Note: Flat side of backing plate faces up.



79



13. Tap the clutch pack side of completed forward clutch housing against the flat work surface to fully seat the snap ring. 14. Check the forward clutch clearance using feeler gauge, as shown in Figure 126, between the backing plate and snap ring. 15. The forward clutch clearance should measure; 1.15 - 1.65 mm (.045" - .065"), as shown in Figure 126. 16. Change the selective backing plate snap ring as necessary to obtain the proper clearance. 17. Install the number 9 thrust bearing into the forward clutch housing, in the direction shown in Figure 127, and retain with liberal amount of Trans-Jel®. 18. Install the number 7 thrust washer, as shown in Figure 128, and retain with Trans-Jel®. 19. Install the number 8 thrust bearing in forward clutch housing, as shown in Figure 128, and retain with liberal amount of Trans-Jel®.

Forward Clutch ClearanceShould Be:

1.15-1.65 mm (.045" - .065")


58 FORWARD CLUTCH NUMBER 7 THRUST WASHER 59 FORWARD CLUTCH NUMBER 8 THRUST BEARING 60 FORWARD CLUTCH SEALING RINGS (2) 61 FORWARD CLUTCH HOUSING ASSEMBLY

61

60

58

59



Figure 127Continued on Page 80

UNIQUE"LAP" JOINT

UNIQUE"LAP" JOINT

60 FORWARD CLUTCH SEALING RINGS (2) 61 FORWARD CLUTCH HOUSING ASSEMBLY

61

60



80



Figure 129

Figure 130


DIRECT CLUTCH HOUSINGCOMPONENT REBUILD

COMPLETED FORWARD CLUTCH HOUSING

20. Install the two forward clutch sealing rings, as shown in Figure 129. Note: Notice the unique "Lap" joint of this set of seal rings, as shown in Figure 129. Ensure they are joined properly. 21. Set the completed forward clutch housing aside for the final drum assembly process, as shown in Figure 130.

1. Disassemble the direct clutch housing using Figure 131 as a guide. 2. Inspect all direct clutch parts thoroughly for any wear and/or damage, replace as necessary. 3. Clean all direct clutch parts thoroughly and dry with compressed air.

Direct Clutch HousingContinued on Page 82



81


57

53

52 51 50 49

5655

49 DIRECT CLUTCH HOUSING ASSEMBLY 50 DIRECT CLUTCH APPLY PISTON 51 DIRECT CLUTCH PISTON "BELLVILLE" RETURN SPRING 52 DIRECT CLUTCH BALANCE PISTON 53 DIRECT CLUTCH BALANCE PISTON SNAP RING 54 DIRECT CLUTCH FRICTION PLATES (4) 55 DIRECT CLUTCH STEEL PLATES (4) 56 DIRECT CLUTCH BACKING PLATE 57 DIRECT CLUTCH BACKING PLATE SNAP RING (SELECTIVE)

DIRECT CLUTCH HOUSING EXPLODED VIEW

54

Figure 131

DIRECT CLUTCH HOUSING

DIRECT CLUTCH HOUSING DIFFERENCES

COMPONENT REBUILD

4. Place the direct clutch housing on a flat work surface, as shown in Figure 133. Note: Ensure that you have the proper direct clutch housing for the model that you are rebuilding (See Figure 132) 5. Lubricate both inner and outer seal surfaces on the new direct clutch piston with Trans-Jel®. 6. Install the direct clutch piston into the direct clutch housing, as shown in Figure 133, using a slight twisting motion.




82



DIRECT CLUTCH HOUSING2003-2004 Models 2005-Up Models

Figure 132

Figure 133

49

50

49 DIRECT CLUTCH HOUSING ASSEMBLY 50 DIRECT CLUTCH APPLY PISTON

NOTICE: At start of production for 2005 model, Ford Motor Co. changed the tooth count on the intermediate friction plates, as shown on Page 73 in Figure 116. This required the direct clutch housing change, as shown in Figure 132, to accommodate the new intermediate frictions.

7. Install direct clutch piston "Bellville" return spring on top of the direct clutch piston in the direction shown in Figure 134. 8. Lubricate the seal and install the direct clutch balance piston, as shown in Figure 134. 9. Compress the return spring and balance piston and install snap ring (See Figure 134). 10. Install 4 steel plates and 4 friction plates in the order shown in Figure 135. 11. Install the direct clutch backing plate and the selective snap ring, as shown in Figure 135.



83


DIRECT CLUTCH HOUSING (CONT'D)


5455

56

49

57

49 DIRECT CLUTCH HOUSING ASSEMBLY 54 DIRECT CLUTCH FRICTION PLATES (4) 55 DIRECT CLUTCH STEEL PLATES (4) 56 DIRECT CLUTCH BACKING PLATE 57 DIRECT CLUTCH BACKING PLATE SNAP RING (SELECTIVE)

51

52

53

49 DIRECT CLUTCH HOUSING ASSEMBLY 51 DIRECT CLUTCH PISTON "BELLVILLE" RETURN SPRING 52 DIRECT CLUTCH BALANCE PISTON 53 DIRECT CLUTCH BALANCE PISTON SNAP RING

49




84


12. Tap the clutch pack side of completed direct clutch housing against the flat work surface to fully seat the snap ring to top of the groove. 13. Check the direct clutch clearance using feeler gauge, as shown in Figure 136, between the backing plate and the snap ring. 14. The direct clutch clearance should measure; 1.14 - 2.06 mm (.045" - .081"), as shown in Figure 136. 15. Change the selective backing plate snap ring as necessary to obtain the proper clearance. 16. Set the completed direct clutch housing aside for the final drum assembly process.

1. Disassemble the forward planetary carrier parts using Figure 137 or 138 as a guide. 2. Inspect all forward planetary carrier parts thoroughly for any wear and/or damage. 3. Clean all forward planetary carrier parts and dry with compressed air.

DIRECT CLUTCH HOUSING (CONT'D) FORWARD PLANETARY SYSTEM

FORWARD PLANETARY SYSTEM DIFFERENCES

COMPONENT REBUILD COMPONENT REBUILD

Forward Planetary CarrierSub Assembly


Figure 136

Direct Clutch ClearanceShould Be:

1.14 - 2.06 mm (.045" - .081")

NOTICE: Beginning at start of production for 2005 models, Ford Motor Co. redesigned the forward planetary system for increased durability. The 2003/2004 version is shown in Figure 137, and the 2005 version is shown in Figure 138, and the differences are as follows: 1. Forward Planetary Carrier. Increased Overall Diameter and Height. Increased Pinion Gear Height. Increased Pinion Pin Diameter. 2. Forward Planetary Carrier Lube Dam. Increased Diameter. 4 Tabs Instead of 6. 3. Number 11 Thrust Bearing. Decreased Diameter. 4. Forward Internal Ring Gear. Increased Overall Diameter and Height. Different Tooth Count For Forward Plates. 5. Number 10 Thrust Washer. Increased Diameter. Different Tab Configuration.

All of these changes are illustrated in Figure 137 and Figure 138.



85





NUMBER 10THRUST WASHER NUMBER 10

THRUST WASHER


LUBE DAM(6 TAB)

LUBE DAM(4 TAB)

FORWARDPLANETARYCARRIER

FORWARDPLANETARYRING GEAR



2003/2004 MODELS 2005/UP MODELS


4. Ensure that you have the proper parts for the model that you are rebuilding. 5. Check forward planetary carrier pinion end play, as shown in Figure 139, and replace the planetary carrier as necessary. 6. If removed, install the proper forward planetary lube dam, as shown in Figure 140, and ensure that all tabs are snapped into position. 7. Install the number 12 thrust bearing into the forward planetary carrier, in the direction that is shown in Figure 140. Note: The number 12 thrust bearing is the same on both models, did not change.

FORWARD PLANETARY SYSTEM (CONT'D)COMPONENT REBUILD




86





LUBE DAM(6 TAB)

LUBE DAM(4 TAB)




Figure 140

Figure 139

If Planetary Pinion End PlayExceeds .030", Replace

Planetary Carrier



87


NUMBER 10THRUST WASHERNUMBER 10

THRUST WASHER








Figure 142

Figure 141

8. Install the proper number 11 thrust bearing in the direction shown in Figure 141, and retain with liberal amount of Trans-Jel®. 9. Install the proper number 10 thrust washer onto the forward ring gear, as shown in Figure 142, with Trans-Jel®.

10. Set the completed forward planetary carrier and the completed forward ring gear aside for the drum assembly process. 11. We are now ready to assemble the drums and and front gear train, but first look at the sun shell differences on Page 89.

FORWARD PLANETARY SYSTEM (CONT'D)COMPONENT REBUILD




88


DRUM AND GEAR TRAIN ASSEMBLIES EXPLODED VIEW


COMPLETED FORWARDCARRIER ASSEMBLY

COMPLETED FORWARDINTERNAL RING GEAR

COMPLETED FORWARDCLUTCH HOUSING

COMPLETED DIRECTCLUTCH HOUSING

Figure 143



89


SUN SHELL DIFFERENCES

SUN SHELL DIFFERENCES

COMPONENT REBUILD

SNAP RINGVISABLE

SNAP RINGNOT VISABLE

LARGER DIAMETER55 TOOTH SUN GEAR

APPROX.1/8" TALLERTHAN 2004

MODELS

SMALLER DIAMETER42 TOOTH SUN GEAR


NOTICE: The sun gear and shell also changed at the start of production for 2005 models so that it would be compatable with the new forward carrier and the visual differences are as follows. 1. Looking at the front of the sun shell assembly it is obvious that the sun gear is larger, and tooth count has been increased to 55 teeth, as shown in Figure 144.

2. Looking at the back of the sun shell assembly you cannot see the retaining snap ring and the bearing support that is pressed onto the sun gear is different configuration, as shown in Figure 144. 3. Setting side by side the 2005 version of the sun shell assembly is approximately 1/8" taller than the 2004 version, as shown in Figure 144.

Figure 144



90


COMPLETED FORWARDCLUTCH HOUSING

COMPLETED FORWARDINTERNAL RING GEAR

COMPLETED DIRECTCLUTCH HOUSING

Ensure Number 9Bearing Is In Place

DRUM AND SUN GEAR SHELL ASSEMBLYCOMPONENT REBUILD



1. Place the completed direct clutch housing on a flat work surface, as shown in Figure 145. 2. Install the completed forward clutch housing assembly, as shown in Figure 145, by rotating back and forth until fully seated and all direct clutch plates engaged on hub. Note: Ensure that number 7 thrust washer and number 8 thrust bearing are still in place with the Trans-Jel®, before installing.

3. Ensure that the number 9 thrust bearing is still in place, as shown in Figure 146. 4. Install completed forward ring gear assembly, as shown in Figure 146, by rotating back and forth to engage the forward clutch frictions, until fully seated. Note: Ensure that number 10 thrust washer is still in place before installing.



91


COMPLETED FORWARDPLANETARY CARRIER


Ensure Number 12Bearing Is In Place


DRUM AND SUN GEAR SHELL ASSEMBLY (CONT'D)COMPONENT REBUILD


5. Install the completed forward planetary carrier, as shown in Figure 147, by rotating into the ring gear until fully seated. Note: Ensure that number 11 bearing is still in place before installing carrier. 6. Install the proper sun gear and shell assembly, as shown in Figure 148, by rotating back and forth until fully seated. Note: Ensure that number 12 thrust bearing is in place, as shown in Figure 148, before installing sun shell.



92


307-436 AND307-436-01


DRUM AND SUN GEAR SHELL ASSEMBLY (CONT'D)COMPONENT REBUILD


7. Ensure that sun gear shell tabs are engaged in the slots of the direct clutch housing, as shown in Figure 149. 8. While holding the assembly together, turn it over so that the assembly is setting on the sun gear, as shown in Figure 150. 9. Install special tools 307-436 and 307-436-01, as shown in Figure 150. 10. Set the completed drum and sunshell assembly aside for the final assembly process.

Ensure that sun shell "Tabs" areengaged into direct clutch housing

slots, as shown above.

If Planetary Pinion End PlayExceeds .030", Replace

Planetary Carrier



93


71 NUMBER 15 THRUST BEARING ASSEMBLY 86 NUMBER 13 AND 14 REAR CARRIER THRUST WASHERS 87 REAR PLANETARY CARRIER ASSEMBLY 88 REAR PLANETARY CARRIER INTERNAL RING GEAR 89 REAR PLANETARY CARRIER INTERNAL RING GEAR HUB 90 REAR PLANETARY CARRIER RING GEAR HUB SNAP RING 91 NUMBER 16 THRUST BEARING ASSEMBLY

REAR PLANET EXPLODED VIEW

86

86

71

87

88

89

90

91


REAR PLANETARY CARRIERCOMPONENT REBUILD


1. Disassemble rear planetary carrier parts using Figure 151 as a guide. 2. Inspect rear planetary carrier parts thoroughly for any wear and/or damage, and replace as necessary Note: There is a new design rear planetary carrier available that has a 2005 part number. Refer to Figure 153 for identification and the new part number. "DO NOT" use "Any" previous design carriers, even if they look good and serviceable. 3. Place the rear planetary carrier on a flat work surface, as shown in Figure 152. 4. Check rear planetary carrier pinion end play using a feeler gauge, as shown in Figure 152. 5. If planetary pinion end play exceeds .030", replacement is necessary.

2003/2004 MODEL"1ST DESIGN"

REAR PLANETARY CARRIER

2005/UP MODEL"2ND DESIGN"

REAR PLANETARY CARRIER

PART NUMBER5C3Z-7DOO6-AB

"DO NOT USE"


Figure 153

Figure 154

1.89

5"

1.77

0"

3.11

0"

2.98

5"

NOTICE: The rear planetary carrier assembly has changed for the 2005 production year because of pinion shafts "walking" in the carrier. The new design rear planetary carrier has a staking process change for the pinion pins to prevent them from "walking" out of the carrier assembly which greatly improves durability and reliability. There have also been some dimensional changes which helps us for identification. The overall height of the carrier has been reduced by .125" (1/8"), as shown in Figure 153. The splines for the low/reverse frictions have also been shortened by .125" (1/8"), as shown in Figure 153.

INTERCHANGEABILITY:

COMPONENT REBUILDREAR PLANETARY CARRIER DIFFERENCES

The new design planetary carrier "Will" retro-fit back on all model years, and is required on any rebuild that has the previous design parts.Note: "Do Not" reuse "Any" previous design rear planetary carriers.



94


REAR PLANETARY CARRIER (CONT'D)COMPONENT REBUILD


6. Install the number 13 thrust washer on the rear planetary carrier, as shown in Figure 154, and retain with Trans-Jel®. Note: If thrust washers are damaged because of previous carrier damage, use OEM part number 3C3Z-7A166-A

Number 13Thrust WasherPart Number

3C3Z-7A166-A

Number 14Thrust WasherPart Number

3C3Z-7A166-A



95





7. Install the number 14 thrust washer on the rear planetary carrier, as shown in Figure 155, and retain with Trans-Jel®. 8. If necessary disassemble the rear planetary ring gear using Figure 156 as a guide. Note: The rear planetary ring gear hub also received a design change for the 2005 model year. The new design has the holes removed from the center, as shown in Figure 156.

Figure 155

Figure 156

2003/2004 MODEL"1ST DESIGN"

REAR RING GEAR HUB

2005/UP MODEL"2ND DESIGN"

REAR RING GEAR HUB

OEM PART NUMBER3C3Z-7D164-AA

"OK TO RE-USE"WITH 2ND DESIGNCARRIER "ONLY"


Figure 159

Figure 158



96






COMPONENT REBUILDContinued on Page 97

9. Assemble the ring gear hub to the ring gear and install the snap ring, as shown in Figure 157. 10. Install number 15 thrust bearing in direction shown in Figure 158, and retain with a small amount of Trans-Jel®. 11. Install number 16 thrust bearing in direction shown in Figure 159, and retain with a small amount of Trans-Jel®. 12. Set the completed rear planetary carrier and the completed rear ring gear aside for the final assembly process.

REAR RING GEARHUB SNAP RING



REAR RINGGEAR HUB

REAR RINGGEAR

COMPLETEDREAR PLANETARY

COMPLETEDREAR RING GEAR



97



S I D ESI UH PT

S I D ESI UH PT

S I D ESI UH PT

Has "Dimple" OnOne Tooth For I.D.

1ST DESIGN LOW DIODE 2ND DESIGN LOW DIODE

Figure 162

Figure 161

LOW ONE WAY CLUTCH DIODE ASSEMBLYCOMPONENT REBUILD

LOW DIODE INNER RACESHOULD FREEWHEEL CLOCKWISEAND LOCK COUNTER-CLOCKWISE

WHILE HOLDING OUTER RACE

1. The low diode assembly received a material change on all pieces of the diode assembly and a small "Dimple" was added to one tooth of the inner race for identification (See Figure 162). Note: "Do Not" install any low diode that does not have the dimple on one tooth. 2. Check the low diode for proper operation, as shown in Figure 161. Note: Low diode inner race should freewheel Clockwise and lock Counter-Clockwise while holding the outer race. 3. Set the low diode assembly aside for the final assembly process.

S I D ESI UH PT

OEM PART NUMBER3C3Z-7A089-AB



98


71 NUMBER 15 THRUST BEARING ASSEMBLY 82 LOW OWC DIODE RETAINING SNAP RING 83 LOW OWC DIODE ASSEMBLY 84 LOW/REVERSE CLUTCH FRICTION PLATES (6) 85 LOW/REVERSE CLUTCH STEEL PLATES (6) 86 NUMBER 13 AND 14 REAR CARRIER THRUST WASHERS 87 REAR PLANETARY CARRIER ASSEMBLY 88 REAR PLANETARY CARRIER INTERNAL RING GEAR 89 REAR PLANETARY CARRIER INTERNAL RING GEAR HUB 90 REAR PLANETARY CARRIER RING GEAR HUB SNAP RING 91 NUMBER 16 THRUST BEARING ASSEMBLY 92 LOW/REVERSE CLUTCH RETURN SPRING SNAP RING 93 LOW/REVERSE CLUTCH RETURN SPRING ASSEMBLY 94 LOW/REVERSE CLUTCH PISTON

LOW/REVERSE CLUTCH PARTS EXPLODED VIEW

86 8671

87 88 8990

91 92

93

94

SID

ES

IU

HP

T

848382

85

Figure 163



99


TRANSMISSION ASSEMBLYINTERNAL COMPONENTS

Figure 164

8485

83

82

S I D ESI UH PT

1. Rotate the case so that bell housing is facing up as shown in Figure 164. 2. Install the complete low/reverse clutch pack, low OWC diode assembly and snap ring, as shown in Figure 164.

3. Check the low/reverse clutch clearance using a feeler gauge, as shown in Figure 165. 4. Low/reverse clutch pack clearance should be; 1.81-3.01 mm (.070" - .120"). 5. Change the selective snap ring as necessary to obtain the proper low/reverse clutch clearance. 6. Remove snap ring and complete low/reverse clutch pack for installation later.

82 LOW OWC DIODE RETAINING SNAP RING 83 LOW OWC DIODE ASSEMBLY 84 LOW/REVERSE CLUTCH FRICTION PLATES (6) 85 LOW/REVERSE CLUTCH STEEL PLATES (6)


Figure 165

Low/Reverse Clutch Clearance Should Be;1.81 - 3.01 mm (.070" - .120")



100

Figure 167

TRANSMISSION ASSEMBLYINTERNAL COMPONENTS (CONT'D)

7. Check the bottom of the case one more time to ensure snap ring for low/reverse clutch piston return spring is seated properly. 8. Install the pre-assembled rear ring gear and thrust bearings, as shown in Figure 166. Note: Ensure number 16 bearing is still in place on back side. 9. Install the 2005 style rear planetary carrier, as shown in Figure 166, by rotating into position. Note: Ensure that number 13 and 14 thrust washers are still in place.


91

88

71

87

71 NUMBER 15 THRUST BEARING ASSEMBLY 87 REAR PLANETARY CARRIER ASSEMBLY 88 REAR PLANETARY CARRIER INTERNAL RING GEAR

Figure 166

10. Re-install low/reverse clutch plates, as shown in Figure 167, beginning with a steel plate and alternating with friction plates, until you have installed six of each. Note: Low/reverse friction plates should be soaked in Mercon SP® before installing.


8485

84 LOW/REVERSE CLUTCH FRICTION PLATES (6) 85 LOW/REVERSE CLUTCH STEEL PLATES (6)




101



83

82

S I D ESI UH PT


82 LOW ONE WAY CLUTCH DIODE RETAINING SNAP RING 83 LOW ONE WAY CLUTCH DIODE ASSEMBLY

S I D ESI UH PT

11. Install the low diode assembly, as shown in Figure 168, with the words "This Side Up" visible after installation. Note: If the low diode is installed correctly, the rear carrier should hold when trying to turn it counter-clockwise, and freewheel in a clockwise direction. 12. Install the low OWC diode retaining snap ring, as shown in Figure 168. Note: The opening of the snap ring should be placed at the one O' clock position.


PRE-ASSEMBLEDDRUMS AND SUNSHELL ASSEMBLY

307-436 AND307-436-01

13. Install the pre-assembled drums and sun gear shell assembly, as shown in Figure 169, using the special tools and rotating into position to engage the sun gear into the rear planetary.





102

CENTER SUPPORTSNAP RING

CENTER SUPPORTASSEMBLY

46

47

48


46 INTERMEDIATE CLUTCH FRICTION PLATES 47 INTERMEDIATE CLUTCH STEEL PLATES 48 INTERMEDIATE CLUTCH BACKING PLATE


14. Install the intermediate clutch backing plate, as shown in Figure 170. 15. Install the intermediate clutch plates, as shown in Figure 170, beginning with a friction plate and alternating with steel plates until you have installed 3 of each. Note: Intermediate friction plates should be soaked in Mercon SP® before installation.


16. Install the pre-assembled center support into case, as shown in Figure 171. 17. Loosely install new center support bolts. 18. Install the center support snap ring, as shown in Figure 171, with the opening facing the six o' clock position in the case.. Note: This snap ring is tapered and the flat side faces downward towards center support.



103



32

30

33

36



19. Install the pre-assembled overdrive ring gear and center shaft, as shown in Figure 172. Note: Ensure the number 5 thrust bearing is still in place on center shaft. 20. Install the pre-assembled coast clutch housing and overdrive carrier assembly, as shown in Figure 173, by rotating into position using the special assembly tool 307 S383. Note: Ensure that number 4 thrust bearing is still in place on overdrive carrier.


33 OVERDRIVE RING GEAR AND CENTER SHAFT ASSEMBLY 36 NUMBER 5 THRUST BEARING ASSEMBLY

30 COAST CLUTCH DRUM AND OVERDRIVE CARRIER ASSEMBLY 32 NUMBER 4 THRUST BEARING ASSEMBLY

ASSEMBLY TOOL307 S383



104



HH

HH

HH

1617

18

19



21. Install the overdrive backing plate snap ring, as shown in Figure 174, with the opening in the six o' clock position in the case. Note: This is a flat snap ring. 22. Install the overdrive clutch backing plate into the case, as shown in Figure 174.

23. Install the overdrive clutch plates, as shown in Figure 174, beginning with a friction plate and alternating with steel plates. Note: Friction plates should be soaked with Mercon SP® before installation. 24. Install alignment dowels 307-456, as shown in Figure 175. 25. Install new pump to case gasket over alignment dowels, as shown in Figure 175.


16 OVERDRIVE CLUTCH FRICTION PLATES (3 REQUIRED). 17 OVERDRIVE CLUTCH STEEL PLATES (3 REQUIRED). 18 OVERDRIVE CLUTCH BACKING PLATE.

11 OIL PUMP ASSEMBLY TO CASE GASKET

11

ALIGNMENTDOWELS307-456

7 OIL PUMP TO CASE RETAINING BOLTS (9 REQUIRED). 8 OIL PUMP ASSEMBLY. 10 PUMP TO COAST CLUTCH DRUM (NO 1) THRUST WASHER. 13 PUMP SUPPORT TO COAST CLUTCH (NO 2) THRUST BEARING.


8

13

10

7KXV9.8

3C3R3C3R3C3R3C3R0701C0701C0701C0701C

KXV9.8

KXV9.8

KXV9.8

KXV9.8

KXV9.8

KXV9.8

KXV9.8

KXV9.8


TORQUE PUMP BOLTS TO27 N•M (20 FT.LB.)


26. Install the pre-assembled oil pump assembly, as shown in Figure 176. Note: Ensure that number 1 thrust washer and number 2 thrust bearing are still in place, on back side of pump. 27. Install the nine new retaining bolts, as shown in Figure 176, and remove the locating dowels. 28. Torque the nine pump to case bolts, as shown in Figure 177, to 27 N•m (20 ft.lb.).



105

Figure 177Figure 176



106

Figure 179

Figure 178



29. Rotate the transmission so that the pan surface is facing up, as shown in Figure 178. 30. Now, torque the new center support bolts to, 32 N•m (24 ft.lb.), as shown in Figure 178. 31. Install the forward clutch orifice on top of the center support bolt, as shown in Figure 179. Note: Retain forward clutch orifice with a small amount of Trans-Jel®. 32. Install a new channel plate to case gasket, as shown in Figure 179, over the locating dowels.

TORQUE NEW FEED BOLTS TO32 N•M (24 FT.LB.)


FORWARDCLUTCHORIFICE

307-456

307-456

CHANNEL PLATETO CASE GASKET



107

Figure 180



33. Install pre-assembled solenoid body assembly, as shown in Figure 180. 34. Install the solenoid body to case bolts in their proper locations, as there are various lengths. Note: Use the chart in Figure 181 for the proper location of the bolts.


SOLENOID BODY ANDCHANNEL PLATE

ASSEMBLY

SOLENOID BODYTO CASE (67.5MM)

(13 REQUIRED)

SOLENOID BODYTO CASE (42 MM)

(3 REQUIRED)REINFORCING PLATE

TO CASE (30 MM)(5 REQUIRED)

35. Use care when pushing case connector through the case bore so as not to damage the "O" ring. 36. Ensure that the manual valve is engaged with the inside detent lever.



108

Figure 181


(3)(27mm)

8 mmHead

8 mmHead

9.8 9.8

Sol. Bodyto Case

(3)(42mm) Sol. Body

to Chan. Plate(1)

(55mm)

8 mmHead

8 mmHead

9.8 9.8

Sol. Bodyto Case

(13)(67.5mm)

8 mmHead

9.8

WireHarness

(2)(15.5mm)

30 TorxHead

"A" "B" "C" "D" "E" "F" "G"

ReinforcingPlate to

Chan. Plate(5)


(5)(30mm)

8 mmHead

9.8

5R110W (Torqshift) VALVE BODY BOLT CHART


PC-A

TCC

SSPC-B

SSPC-C

SSPC-E

SSPC-D

SSPC-A

A

A

A

A

C

C

C

C

CA

F F D B

B

B

D

G

G

D

E

FF

F

F

F

F

F F

F

F

F




109

Figure 182


INTERNAL COMPONENTS (CONT'D)

37. Torque all of the solenoid body retaining bolts to 10 N•m (89 in.lb.), beginning in the center and working in a circle outward. 38. Install the transmission range sensor connector, as shown in Figure 182. 39. Install a new pan gasket on the case surface, as shown in Figure 182. Note: Pan gasket is reuseable as long as no beads are broken.



FLUID FILTER

FLUID PAN GASKET(REUSABLE)

CONNECT THE TRANSMISSIONRANGE SENSOR CONNECTOR

FILTER SEAL

40. Install a new fluid filter and seal, as shown in Figure 182. Note: Be sure old filter seal has been removed from pump bore before installing filter. 41. Ensure that all internal harness connectors are connected properly.



110


42. Install the oil pan, as shown in Figure 183, and install the 20 pan bolts. 43. Torque pan bolts to 15 N•m (11 ft.lb.).


PAN BOLTS(20 REQUIRED)

PAN

ISEQ

UIPP

EDW

ITH

ARE

USAB

LEGA

SKET

FordFord


Figure 183



111



44. Rotate the transmission in fixture so that oil pan is facing down. 45. Check turbine/intermediate shaft speed sensor as shown in Figure 184. 46. Install new "O" ring on turbine/intermediate speed sensor, as shown in Figure 185.

47. Lubricate "O" ring and install the speed sensor as shown in Figure 185. 48. Torque speed sensor bolt to 9 N•m (80 in.lb.).


(1)

(2)

(3)

(4)


Speed Sensor

Gray/Orange

Green/White

Pink/White

Black/White



TSS Sig

Grnd

Ref Volt

ISS Sig




Figure 184

FordFord

RETAININGBOLT

"O" RING

TURBINE/INTERMEDIATESHAFT SPEED SENSOR

Figure 185




112

Figure 187


RETAININGBOLTOUTPUT SHAFT

SPEED SENSOR

OUTPUT SHAFTSPEED SENSOR

"O" RINGEXTENSIONHOUSING




Pink/White(1)

(2)

(3)Black/White

Blue/Yellow


Grnd

Ref Volt

OSS Sig


Figure 186


RF3C3P-7006-AE

FordFord

98

3C3P-7000-KB F5A4522 180302

DDMMYYPDT-25

A1F5

Figure 188


51. Lubricate "O" ring and install the speed sensor as shown in Figure 187. 52. Torque speed sensor bolt to 9 N•m (80 in.lb.). 53. Install turbine shaft as shown in Figure 188.


49. Check the output shaft speed sensor, as shown in Figure 186. 50. Install new "O" ring on output shaft speed sensor, as shown in Figure 187.



113

Figure 189

Figure 190


TRANSMISSIONHOLDING FIXTURE

RF3C3P-7006-AE

FordFord

98

3C3P-7000-KB F5A4522 180302

DDMMYYPDT-25

A1F5


54. Remove the transmission holding fixture, as shown in Figure 189. 55. Congratulations, You Are Finished.

TORQUE SPECIFICATIONS

DESCRIPTION N·m ft.lbs. in.lbs.

27

31

24

24

10

10

10

150 110

9

10

47

30

18

36

200 148

8-16

33

15

Oil Pump Assembly to Case (9)

Oil Pump Cover to Oil Pump Body (8)

Stator Shaft to Oil Pump Cover (3)

Center Support Feed Bolts (2)

Solenoid Body Bolts (All)

Spacer Plate Reinforcing Plate to Channel Plate (4)

Transmission Range Sensor to Case (2)

Line Pressure Plug (1)

Parking Pawl Abutment Plate to Case (1)

Parking Pawl Guide Plate to Case (2)

Extension Housing Bolts (9)

Front Cooler Line Connector to Case (1)

Rear Cooler Line Connector to Case (1)

Speed Sensors to Case (2)

Output Shaft Nut 4WD (1)

Output Shaft Flange Nut 2WD (1)

Transmission Oil Pan to Case (20)

Transmission Oil Pan Drain Plug (1)

20

23

11

33

6-12

18

18

24

35

22

27

89

89

89

89

80



114



(3)(27mm)

8 mmHead

8 mmHead

9.8 9.8

Sol. Bodyto Case

(3)(42mm) Sol. Body

to Chan. Plate(1)

(55mm)

8 mmHead

8 mmHead

9.8 9.8

Sol. Bodyto Case

(13)(67.5mm)

8 mmHead

9.8

WireHarness

(2)(15.5mm)

30 TorxHead

"A" "B" "C" "D" "E" "F" "G"

ReinforcingPlate to

Chan. Plate(5)


(5)(30mm)

8 mmHead

9.8

5R110W (Torqshift) VALVE BODY BOLT CHART


A

A

A

A

C

C

C

C

CA

F F B D

D

D

B

G

G

B

E

FF

F

F

F

F

F F

F

F

F

Figure 191

9.8

9.8

9.8

13 mmHead

13 mmHead

13 mmHead

ExtnHsng

(2)(92mm)

ExtnHsng

(7)(40mm)

ExtnHsng

(1 Some)(40mm)

13 mmHead

"PTO"Cover

(6)(19mm)

13 mmHead

CenterSupport

(2)(30mm)

9.8

9.8KXV

10 mmHead

Pump Coverto Pump Body

(8)(45mm)

9.8J

10 mmHead

Pump toCase(9)

(65mm)

10 mmHead

Oil Panto Case

(20)(14mm)

9.8

StatorShaft

(3)(17mm)

30 TorxHead

13 mmHead

9.8

Park RodGuide Plate

(2)(23mm)

BOLTS DRAWNACTUAL SIZE

BOLT CHART




115


Figure192



116


SPECIAL TOOLS


Figure 193

2WD Extension Housing Seal Installer

307-462

4WD Extension Housing Seal Installer

307-453

Clutch Spring Compressor

307-015

Manual Shift Lever Seal Installer

307-002

Output Shaft Bushing Installer

307-464

Torque Converter Handles

307-091



117


SPECIAL TOOLS


Figure 194

Oil Pump Alignment Dowel

307-222

Filler Tube Installer

307-376

Forward Clutch And Sun Shell Assembly Installer

307-436

Bridge Adapter (Use With 370-436)

307-436-01

Coast Clutch Loading Fixture

307-S383

Air Test Plate

307-457



118


SPECIAL TOOLS


Figure 195

Air Test Plate Bolt Kit

307-126

Alignment Cone

307-455

Output Shaft Nut Driver

307-458

Seal Pack Installer(Rear Of Case)

307-461

Torque Converter Retainer

307-346

Center Support Snap Ring Pliers

307-343



119


SPECIAL TOOLS


Figure 196

Pump Alignment Pins

307-456

Handle

205-153



120

NotesNotes

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